Modine Manufacturing HDS 30, HDS 45, HDS 60, HDC 60, HDS 75 Service Manual
...
INSTALLATION AND SERVICE MANUAL
separated combustion gas-fired unit heaters
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
WHAT TO DO IF YOU SMELL GAS:
1. Open windows.
2. Do not try to light any appliance.
3. Do not touch any electrical switch; do
not use any phone in your building.
4. Immediately call your gas supplier
from a neighbor’s phone. Follow the gas
supplier’s instructions. If you can not reach
your gas supplier, call your fire department.
6-584.3
5H80002A
September, 2010
model HDS and HDC
All models approved for use in California by the CEC, in New
York city by the MEA division, and in Massachusetts. Unit heater
is certified for residential and commercial applications.
FOR YOUR SAFETY
The use and storage of gasoline or other
flammable vapors and liquids in open containers
in the vicinity of this appliance is hazardous.
IMPORTANT
The use of this manual is specifically intended
for a qualified installation and service agency.
All installation and service of these units must
be performed by a qualified installation and
service agency.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report it
immediately to transportation company and your local
Modine sales representative.
2.
Check rating plate on unit to verify that power supply meets
available electric power at the point of installation.
3. Inspect unit upon arrival for conformance with description of
product ordered (including specifications where applicable).
Table of Contents
Inspection on Arrival................................. 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
Venting ....................................... 6
Gas Connections............................... 12
Electrical ..................................... 13
Operation..................................... 14
Unit Components .................................. 15
Dimensions....................................... 16
Service/Trouble Shooting ............................ 17
Unit Wiring Diagram ................................ 18
Serial/Model Number/Replacement Parts ............... 19
Commercial Warranty............................... 20
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
SPECIAL PRECAUTIONS
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS
MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT
AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR
CARE MUST BE EXERCISED REGARDING THE SPECIAL
PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS
THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE
OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS
SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL
CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
dANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
WARNING
1. Gas fired heating equipment must be vented - do not
operate unvented.
2. A built-in power exhauster is provided - additional external
power exhausters are not required or permitted.
3. If you are replacing an existing heater, 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 or CSA B149.1 latest edition. Failure to follow these
instructions can result in injury or death.
4. Under no circumstances should two sections of double wall
vent pipe be joined together within one horizontal vent system
due to the inability to verify complete seal of inner pipes.
5. All field gas piping must be pressure/leak tested prior to
operation. Never use an open flame. Use a soap solution
or equivalent for testing.
6. Gas pressure to appliance controls must never exceed 14"
W.C. (1/2 psi).
7. To reduce the opportunity for condensation, the minimum
sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input,
or 5% below the minimum rated input of dual rated units.
8. Disconnect power supply before making wiring connections
to prevent electrical shock and equipment damage.
9. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
different from the wiring diagram could result in a hazard to
persons and property.
10. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
11. Ensure that the supply voltage to the appliance, as indicated
on the serial plate, is not 5% greater than the rated voltage.
12. When servicing or repairing this equipment, use only
factory-approved service replacement parts. A complete
replacements parts list may be obtained by contacting
the factory. Refer to the rating plate on the appliance for
complete appliance model number, serial number, and
company address. Any substitution of parts or controls not
approved by the factory will be at the owners 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. Low profile heaters are designed for use in heating applica tions with ambient 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, 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 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.
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) and 5' measured from the bottom of the unit
to the floor in residential applications.
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 6" 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, with Part 7, Venting of Equipment,
of 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.
16. 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 CSA-B149 codes.
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).
2
6-584.3
SPECIAL PRECAUTIONS / SI (METRIC) CONVERSION FACTORS
BEFORE YOU BEGIN
cAUTION
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 not 5% less than 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. Servicing or repairing of this equipment must be
performed by a qualified service agency.
23. Do not attempt to reuse any mechanical or electronic
ignition controllers which has been wet. Replace defective
controller.
IMPORTANT
1. To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) 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 13 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 17.1 refer to the applicable
sections of the manual.
cAUTION
1. All literature shipped with this unit should be kept for future
use for servicing or service diagnostics. Leave manual with
the owner. Do not discard any literature shipped with this unit.
2. Consult piping, electrical, and venting instructions in this
manual before final installation.
3. Do not attach ductwork, air filters, or polytubes to any
propeller unit heater.
In the U.S., the installation of these units must comply with the
“National Fuel Gas Code,” ANSI Z223.1, latest edition (also
known as NFPA 54) and other applicable local building codes.
In Canada, the installation of these units must comply with local
plumbing or waste water codes and other applicable codes and
with the current code CSA-B149.1.
1. All installation and service of these units must be
performed by a qualified installation and service agency
only as defined in ANSI Z223.1, 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. The right is reserved to
substitute other authorized controls as replacements.
3. Unit is balanced for correct performance. Do not alter fan
or operate motors at speeds below what is shown in this
manual.
4. Information on controls is supplied separately.
5. The same burner is used for natural and propane gas.
SI (METRIC) CONVERSION FACTORS
To Convert Multiply By To Obtain
"W.C. 0.249 kPa
°F (°F-32) x 5/9 °C
Btu 1.06 kJ
Btu/ft3 37.3 kJ/m
Btu/hr 0.000293 kW
CFH (ft3/hr) 0.000472 m3/min
CFH (ft3/hr) 0.00000787 m3/s
CFM (ft3/min) 0.0283 m3/min
CFM (ft3/min) 0.000472 m3/s
To Convert Multiply By To Obtain
feet 0.305 m
Gal/Hr. 0.00379 m3/hr
Gal/Hr. 3.79 l/hr
3
gallons 3.79 l
Horsepower 746 W
inches 25.4 mm
pound 0.454 kg
psig 6.89 kPa
psig 27.7 "W.C.
6-584.3
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. Low profile heaters are designed for use in heating applica tions with ambient 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,
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 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 accor-
dance 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.
Table 4.1 - Clearances
Unit Side Clearance To Recommended
Combustible Materials Service Clearance
Top and Bottom 1" 1"
Access Side 1" 18"
Non-Access Side 1" 1"
Rear 18" 18"
Vent Connector 4" 4"
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 16 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.
Turning The Unit 180° (Model Sizes 30-75 Only)
All units are produced at the factory with left-side controls (when
looking at the unit). If the installation requires the controls to
be on the right side, all HDS/HDC heaters - with the exception
of the 100 and 125 - can be turned-over by following the
instructions below.
• Byturningtheunit180°fromthewayitwasreceivedfrom
the factory, the sides become opposite but the front and
back remain in the same relative position. The bottom panel
now becomes the top panel and vice-versa.
• Removetheaccesspanel,turnit180°,andre-attachitto
the unit so that all the information labels can be read.
• Removethespringloadeddeflectorblades,turnthemover,
replace, and adjust so they are open and in a position to
direct the heated air down to the floor.
IMPORTANT
To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the
atmosphere.
Location Recommendations
1. When locating the heater, consider general space and
heating requirements, availability of gas and electrical
supply, and proximity to vent locations.
2. When locating units, it is important to consider that the
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. 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 Table 4.1.
4
6-584.3
UNIT MOUNTING
cAUTION
1.
Do not install units below 7' measured from the bottom of
the unit to the floor in commercial applications (unless
unit is properly guarded to provide user protection from
moving parts) and 5' measured from the bottom of the unit
to the floor in residential applications.
2. Be sure no obstructions block air intake and discharge
of unit heaters.
3. The minimum distance from combustible material is
based on the combustible material surface not exceeding
160°F. Clearance from the top of the unit may be required
to be greater than the minimum specified if heat damage,
other than fire, may occur to materials above the unit
heater at the temperature described.
4. Allow 18" clearance at rear (or 6" beyond end of motor
at rear of unit, whichever is greater) and access side to
provide ample air for proper operation of fan.
Figure 5.2 - Unit Heater Turned 180° (30-75 units only)
(Access panel and heated air outlet change sides)
1. Be sure the means of suspension is adequate to support
the weight of the unit (see page 16 for unit weights).
2. For proper operation, the unit must be installed in a level
horizontal position.
3. Clearances to combustibles as previously specified must be
strictly maintained.
4. For model sizes 30-75, before lifting the heater for
suspension, the mounting brackets must be installed as
follows (for bracket accessory installation on model sizes
100-125, see the latest revision of literature 6-594):
•Forstandard(leftside)controlaccess,removethe(3)
screws and mounting bracket along the top edge of both
the front and back of the unit. Install the front bracket as
shown in Figure 5.1 by aligning the screw holes on the
bracket with the screw holes on the top edge of the unit.
Repeat for the bracket on the back of the unit.
•Forrightsidecontrolaccess,removethe(3)screwsand
mounting bracket along the top edge of both the front and
back of the unit. Turn the unit over and install the front
bracket as shown in Figure 5.2 by aligning the screw holes
on the bracket with the screw holes on the top edge of the
unit (originally the bottom edge). Repeat for the bracket on
the back of the unit.
5a. Suspension by screws/lag bolts: Secure the mounting
brackets to the ceiling joists or truss, using 1/4" screws with
1/2" washers. These unit mounting brackets are slotted to
accommodate joists on 16" or 24" centerlines. See page 16
for mounting bracket dimensions.
Figure 5.1 - Unit Heater in Standard Mounting
Configuration (30-75 Units Only)
5b. Suspension by threaded rod: The unit can also be hung
with threaded rod utilizing the same mounting brackets.
Attach the threaded rod to the unit mounting brackets,
securing with a top and bottom nut. For model sizes
100-125, the units are designed to be suspended by
threaded rod without the use of brackets. On each piece of
3/8" threaded rod used, screw a nut a distance of about one
inch onto the end of the threaded rods that will be screwed
into the unit heater. Place a washer over the end of the
threaded rod and screw the threaded rod into the unit heater
weld nuts on the top of the heater at least 5 turns, and no
more than 10 turns. Tighten the nut first installed onto the
threaded rod to prevent the rod from turning.
Next, drill holes into a steel channel or angle iron at the
same centerline dimensions as those chosen for the heater
being installed. The steel channels or angle iron pieces need
to span and be fastened to appropriate structural members.
Cut the threaded rods to the preferred length, push them
through the holes in the steel channel or angle iron and
secure with washers and lock nuts, lock washers and nuts,
or a washer with double nut arrangement.
NOTE: A pipe hanger adapter kit, shown in Figure 5.3, is
available as an accessory. One kit consists of two drilled
3/4" IPS pipe caps and two 3/8 - 13 x 1-3/4" capscrews
to facilitate threaded pipe suspension. Two kits would be
required.
5c. Shelf mounted units: The unit heater can also be installed
on a shelf. The mounting brackets will need to be attached
to the heater the same manner as explained in note #4,
however, to mount on a shelf the brackets must go on the
bottom of the heater. The brackets must be affixed to the
shelf using similar screws (1/4" screw with 1/2" washer) as
overhead joist or truss mounting. Be sure all clearance to
combustible requirements are met.
Figure 5.3 - Unit Heater Suspension Methods
(Threaded Rod) (Pipe Adaptor Kit)
6-584.3
5
INSTALLATION - VENTING
WARNING
1. Gas fired heating equipment must be vented - do not operate
unvented.
2. A built-in power exhauster is provided - additional external
power exhausters are not required or permitted.
3. If you are replacing an existing heater, 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 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 Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest
edition. In Canada installation must be in accordance with CSA
B149.1.
Model HDS/HDC 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:
Instructions Applicable Installation Instructions
Section by Vent System Type
A General instructions for ALL installations
B VERTICAL 2-PIPE vent systems ➀
C HORIZONTAL 2-PIPE vent systems ➀
D HORIZONTAL AND VERTICAL
CONCENTRIC vent systems ➀
➀The differences between Vertical and Horizontal vent systems in 2-Pipe or
Concentric Vent configurations will be identified in “Section A - General
Instructions – All Units”.
A4. Limit the total equivalent vent pipe length to a minimum
of 3' and a maximum of 25', making the vent system as
straight as possible. The equivalent length of a 3" elbow is
1' and for a 4" elbow is 5'.
A5. A minimum of 12" straight pipe is recommended from the
flue outlet before turns in the vent pipe.
A6. Horizontal sections of vent pipe are to be installed with a
minimum downward slope from the appliance of 1/4 inch
per foot and suspended securely from overhead structures
at points not greater than 3' apart.
A7. Fasten individual lengths of vent together with at least three
corrosion resistant sheet metal screws.
A8. Keep single wall vent pipe at least 6" from combustible
materials. For double wall vent pipe, follow the vent
pipe manufacturer’s clearances to combustibles. The
minimum distance from combustible materials is based
on the combustible material surface not exceeding 160°F.
Clearance from the vent pipe (or the top of the unit) may be
required to be greater than 6" if heat damage other than fire
could result (such as material distortion or discoloration).
A9. Avoid venting through unheated space when possible.
When venting does pass through an unheated space or
if the unit is installed in an environment that promotes
condensation, insulate runs greater than 5' to minimize
condensation. Inspect for leakage prior to insulating and
use insulation that is noncombustible with a rating of not
less than 400°F. Install a tee fitting at the low point of the
vent system and provide a drip leg with a clean out cap as
shown in Figure 8.1.
A10. When the vent passes through a combustible INTERIOR
wall or floor, a metal thimble 4" greater than the vent
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
Figure 6.1 - Venting Through Combustible Roof
or Wall
Single Wall Vent Pipe
Flashing
Specified
Terminal
Double Wall Vent Pipe ➀
Flashing
Specified
Terminal
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 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 combustion air pipe and 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.
A3. All heaters come with factory installed vent and combustion
air adapters for attaching the vent pipe to the heater (3" for
model sizes 30-45, 4" for model sizes 60-125). 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.
6
Listed
Thimble
Single
Wall
Single Wall Vent Pipe Terminating
with Double wall vent pipe. ➀
Clearance Specified
by Type B Vent Mfg.
Single Wall Vent Pipe
Listed
Thimble
➀ See Instruction A12 for attaching single wall pipe to double wall pipe
6-584.3
Clearance Specified
by Type B Vent Mfg.
Double
Wall
Specified
Terminal
Single
Wall
Specified
Terminal
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