Service manual

ManualsBrandsModine Manufacturing ManualsGas HeaterBD

July, 2003

INSTALLATION AND SERVICE MANUAL

gas-fired unit heaters

models PD and BD

6-553.4

5H73889A Rev. E

WARNING

Improper installation, adjustment,

alteration, service or maintenance can cause

property damage, injury or death, and could

cause exposure to substances which have

been determined by various 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.

All models approved for use in California by the CEC (when

equipped with IPI), in New York by the MEA division, and in

Massachusetts. Unit heater is certified for non-residential

applications.

Inspection on Arrival

1. Inspect unit upon arrival. In case of damage, report

immediately to transportation company and your local

Modine sales representative.

Check rating plate on unit to verify that power supply meets

available electric power at the point of installation.

3. Inspect unit received for conformance with description of

product ordered (including specifications where applicable).

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Don’t touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

CAUTION

To prevent premature heat exchanger failure

do not locate ANY gas-fired units in areas

where chlorinated, halogenated, or acid vapors

are present in the atmosphere.

IMPORTANT

The use of this manual is specifically intended

for a qualified installation and service agency.

A qualified installation and service agency must

perform all installation and service of these

appliances.

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.

THIS MANUAL IS THE PROPERTY OF THE OWNER.

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

Summary of content (32 pages)

PAGE 1
6-553.4 5H73889A Rev. E July, 2003 INSTALLATION AND SERVICE MANUAL gas-fired unit heaters models PD and BD All models approved for use in California by the CEC (when equipped with IPI), in New York by the MEA division, and in Massachusetts. Unit heater is certified for non-residential applications. FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. Don’t touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier.
PAGE 2
SPECIAL PRECAUTIONS / TABLE OF CONTENTS SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES. HAZARD INTENSITY LEVELS 1.
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SI (METRIC) CONVERSION FACTORS / UNIT LOCATION SI (METRIC) CONVERSION FACTORS Table 3.1 To Convert Multiply By To Obtain "W.C. 0.24 kPa psig 6.893 kPa °F (°F-32) x 0.555 °C inches 25.4 mm feet 0.305 meters CFM 0.028 m3/min To Convert Multiply By To Obtain CFH 1.699 m3/min 3 Btu/ft 0.0374 mJ/m3 pound 0.453 kg Btu/hr 0.000293 kW/hr gallons 3.785 liters psig 27.7 "W.C. 11.
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UNIT LOCATION Sound and Vibration Levels All standard mechanical equipment generates some sound and vibration that may require attenuation. Libraries, private offices and hospital facilities will require more attenuation, and in such cases, an acoustical consultant may be retained to assist in the application. Locating the equipment away from the critical area is desirable within ducting limitations. Generally, a unit should be located within 15 feet of a primary support beam.
PAGE 5
INSTALLATION Venting WARNING 1. Gas fired heating equipment must be vented - do not operate unvented. 2. A built-in draft diverter is provided - additional external draft diverters are not required or permitted. 3. Gas-fired heating equipment which has been improperly vented, or which experiences a blocked vent condition may have flue gasses accidentally spilled into the heated space. See page 15 for specific information about the blocked vent safety switch supplied on the unit. 4.
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INSTALLATION ADDITIONAL VENTING REQUIREMENTS FOR CATEGORY II UNITS Table 6.1 Minimum Height from Roof to Lowest Discharge Opening Vent system must provide for drainage of condensate. At the low point of the vent system, install a tee fitting with a connector and attach flexible tubing, minimum 3/8 inch I.D., and run to a drain. Tee fitting and associated condensate disposal system must be periodically cleaned.
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INSTALLATION Gas Connections WARNING 1. All field gas piping must be pressure/leak tested prior to operation. Never use an open flame. Use a soap solution or equivalent for testing. 2. Gas pressure to appliance controls must never exceed 14" W.C. (1/2 psi). 3. To reduce the opportunity for condensation, the minimum sea level input to the appliance, as indicated on the serial plate, must not be less than 5% below the rated input, or 5% below the minimum rated input of duel rated units. 3. 4. CAUTION 5.
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INSTALLATION Electrical Connections WARNING 1. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage. 2. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property. 3. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C. 4.
PAGE 9
INSTALLATION Figure 9.1- Typical Duct & Airflow Installation Dimension “B” Should Never Be Less than 1/2 of “A” Recommended Installations A TURNING VANES 3" MIN. B 3" MAX. C 12" MIN. 3" MIN. B B 12" MIN. 12" A 3" MAX. B 12" MIN. A A TURNING VANES BAFFLE SIDE VIEW TOP VIEW SIDE VIEW D E F 12" MIN. 12" MIN. B B A TURNING VANES BAFFLE SIDE VIEW A TURNING VANES BAFFLE SIDE VIEW IMPORTANT Do not attempt to attach ductwork of any kind to propeller models.
PAGE 10
INSTALLATION To Install 1. Remove and discard the motor tie down strap and the shipping block beneath the belt tension adjusting screw (Not used on all models.) Figure 10.1 Blower Model THREADED ROD MOUNTING BRACKETS ON BLOWER ASSEMBLY MOTOR MOUNTING BRACKET BLOWER SHEAVE MOTOR ADJUSTMENT SCREW BLOWER HOUSING MOTOR SHEAVE 2. Adjust motor adjusting screw for a belt deflection of approximately 3/4" with five pounds of force applied midway between the sheaves (refer to Figure 10.3).
PAGE 11
START-UP PROCEDURE IMPORTANT 1. To prevent premature heat exchanger failure, observe heat exchanger tubes. If the bottom of the tubes become red while blower is in operation, check to be sure the blower has been set to the proper rpm for the application. Refer to pages 9 and 10 for Blower Adjustments. 2. Start-up and adjustment procedures should be performed by a qualified service agency. 1. Turn off power to the unit at the disconnect switch.
PAGE 12
START-UP PROCEDURE Figure 12.2 Typical Combination Gas Control Figure 12.1 Correct Pilot Flame 3/4" to 1" GAS CONTROL KNOB PRESSURE REGULATOR ADJUSTMENT SCREW (UNDER CAP SCREW) INLET PRESSURE TAP OUTLET PRESSURE TAP OUTLET INLET PILOT TUBING CONNECTION RESET BUTTON PILOT ADJUSTMENT SCREW Main Burner Adjustment Burner Flame Adjustment The gas pressure regulator (integral to the combination gas control) is adjusted at the factory for average gas conditions.
PAGE 13
START-UP PROCEDURE Table 13.1 Manifold Pressure & Gas Consumption BTU/Cu. Ft. Model Specific Gravity Manifold Pressure In. W.C. Figure 13.2 - Air Shutter Adjustment, Propane Gas ➀ MANIFOLD Natural 1050 0.60 3.5 Propane 2500 1.53 10.0 No. of Orifices PD 30 CFH Gal/Hr. Propane Orifice Drill Size 28.6 – 38 12.0 .33 52 1 PD 50 BD 50 CFH Gal/Hr. Propane Orifice Drill Size 47.6 – 30 20.0 .55 45 1 PD 75 BD 75 CFH Gal/Hr. Propane Orifice Drill Size 71.4 – 21 30.0 .
PAGE 14
START-UP PROCEDURE Two-Stage Gas Controls (standing pilot) Utilizes a two-stage combination gas control with a standing pilot operator and a two-stage low voltage thermostat. The unit fires at 50% fire on low stage and 100% fire on high stage. 1. Pilot is lit continuously. 2. Thermostat calls for heat. 3. The main gas valve is opened and the main burner is lit to 50% fire. 4. The air mover starts after 30 to 90 seconds. 5.
PAGE 15
Figure 15.1 Factory Mounted Option Location ➇ ➈ ➆ ➅ ➃ ➁ ➀ ➄ ➂ All units include the standard (STD) features. The unit must be reviewed to determine the optional (OPT) features that may have been supplied with the unit. (1) Gas Valve a) Single Stage Gas Valve - (STD) The main gas valve is factory installed on the unit heater gas train. The main gas valve provides the pilot, regulator, main gas, and manual shutoff functions.
PAGE 16
OPTIONS (5) Control Step Down Transformer - (STD) The control step down transformer is located in the electrical junction box. The transformer is used to step down the supply power (115V, 208V, 230V, 460V, 575V) to 24V. This transformer is used to control the gas controls, fan delay relay, field supplied motor starter, etc. All unit heaters are supplied with a 40VA control step down transformer.
PAGE 17
GENERAL PERFORMANCE DATA Table 17.1 - Performance — Propeller Models ➀ ➁ Standard PD 30 Btu/Hr. Input 30,000 Btu/Hr. Output 24,000 Entering Airflow (CFM) 440 Outlet Velocity 515 Air Temp. Rise (°F) 51 Max. Mounting Hgt. (Ft) ➂ 7 Heat Throw (Ft) ➂ (Max. Mtg. Hgt.
PAGE 18
GENERAL PERFORMANCE DATA Blower Models Models With or Without Blower Enclosure ➀ ➁ For 575V selections and footnotes, please see page 19. 0.0 Static Air Pressure 0.1 Static Air Pressure 0.2 Static Air Pressure 0.3 Static Air Pressure 0.4 Static Pressure Temp Sheave Sheave Sheave Sheave Sheave Model Rise Airflow RPM HP Drive Turns RPM HP Drive Turns RPM HP Drive Turns RPM HP Drive Turns RPM HP Drive Turns No. (°F) (cfm) No. Open No. Open No. Open No. Open No.
PAGE 19
GENERAL PERFORMANCE DATA Blower Models Filters Models With or Without Blower Enclosure ➀ ➁ Data for use with filters only For blower units with enclosure and filter, add the following static pressures to the static pressure determined by the system designer for total external static pressure. 0.5 Static Air Pressure 0.6 Static Air Pressure 0.7 Static Air Pressure Temp Sheave Sheave Sheave Model Rise Airflow RPM HP Drive Turns RPM HP Drive Turns RPM HP Drive Turns No. (°F) (cfm) No. Open No. Open No.
PAGE 20
GENERAL PERFORMANCE DATA TABLE 20.
PAGE 21
GENERAL PERFORMANCE DATA TABLE 21.2 Blower Drive Numbers Drive No. -1 -2 -6 -23 -24 -25 -38 -61 -80 -83 -90 -91 -92 -95 -96 -100 -101 -102 -105 Blower Sheave Motor Sheave Blower Sheave Motor Sheave Drive Belt No. Pitch Max. Pitch Belt No. Pitch Max. Pitch No. Bore Bore Bore Bore Browning Dia. Dia. Browning Dia. Dia. A29 A30 A48 A56 A56 A58 A41 A30 A45 A43 A35 A33 A36 A42 A43 A50 A50 A49 A54 4 5 8 11 13 13 6 4 7 6 6 4 6 7 7 8 9 9 10 3/4 3/4 1 1 1 1 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1 1 1 2.9 2.9 2.
PAGE 22
PERFORMANCE DATA – NOZZLES 90° VERTICAL NOZZLE H H T S S S 40° DOWNWARD NOZZLE 5-WAY NOZZLES T H T S 40° SPLITTER NOZZLE S S Mounting Height, Heat Throw, Heat Spread (in feet) Model Number Nozzle Type 40° Downward Nozzle 90° Vertical Nozzle 40° Splitter Nozzle 5-Way Nozzle BD 50 BD 75 16 20 21 24 26 25 27 29 31 32 32 Heat Throw (ft.) T 48 61 64 71 79 76 81 86 94 96 96 Max. Mounting Ht. (ft.
PAGE 23
PERFORMANCE DATA – HOODS FOR PROPELLER MODELS Performance Data — 30°, 60° and 90° Downward Deflector Hoods Mounting Height to Bottom of Heater Models 8' 10' 12' 14' 16' 18' 20' 22' 24' 30° Downward Hood For Propeller Units ➀ PD 50 PD 75 X Y Z X Y Z 8 19 26 11 25 34 6 15 22 9 23 22 4 12 17 7 20 28 5 14 21 PD 100 X Y Z 14 31 43 13 30 41 11 28 39 10 25 35 5 17 25 Mounting Height to Bottom of Heater Models 8' 10' 12' 14' 16' 18' 20' 22' 24' 8' 10' 12' 14' 16' 18' 20' 22' 24' 26' 28' 30' PD 150 X Y Z 16 3
PAGE 24
PERFORMANCE DATA – HOODS FOR BLOWER MODELS Performance Data — 30°, 60° and 90° Downward Deflector Hoods Mounting Height to Bottom of Heater Models 8' 10' 12' 14' 16' 18' 20' 22' 24' 26' 28' 30' 30° Downward Hood For Blower Units ➁ BD 50 X Y Z 13 29 40 12 28 38 10 25 35 8 21 30 BD 75 X Y Z 18 38 52 16 37 50 15 35 48 14 33 46 12 30 42 9 25 36 BD 100 X Y Z 22 47 64 21 46 63 20 45 61 19 43 59 17 41 57 16 39 54 14 35 50 11 30 43 Mounting Height to Bottom of Heater Models 8' 10' 12' 14' 16' 18' 20' 22' 24'
PAGE 25
DIMENSIONAL DATA Propeller Units - Model PD Figure 25.1 Dimensional Drawings C A H F J VENT PIPE X W K G AA K E B BB EE LL L - Approx D (OPENING) MIN. DISTANCE L TO WALL IS L + 6" (MIN. DISTANCE TO WALL) Table 25.1 Dimensions (inches) — PD ➀ Dimension Symbol PD 30 A 12-7/8 B 24-1/4 C 14-3/4 D 10-7/16 E 13 F 9-1/4 G 2 H 9-1/4 J➁ 3 K (Mounting 3/8-16 Holes) ➂ L➃ 28-1/4 W – X – AA 5 BB 6-1/4 EE 22-1/4 LL 19-1/2 Gas Connections ➄ 1/2 Fan Diameter 9 Approx.
PAGE 26
DIMENSIONAL DATA Blower Units - Model BD Figure 26.1 Dimensional Drawings C A F H W J VENT PIPE N EE P X K 4-5/8'' S G AA O QxV K E B RxT BB BLOWER FILTER RACK ENCLOSURE (OPTIONAL) (OPTIONAL) L (MIN. DISTANCE TO WALL) M (APPROX.) D (OPENING) L (MIN. DISTANCE TO WALL) Table 26.
PAGE 27
MAINTENANCE All heating equipment should be serviced before each heating season to assure proper operations. The following items may be required to have more frequent service schedule based on the environment in which the unit is installed, and the frequency of the equipment operation. General Unit When providing annual maintenance for the unit heater, keep the unit free from dust, dirt, grease and foreign matter. Pay particular attention to: 1. The combustion air and exhaust vent piping. 2.
PAGE 28
SERVICE & TROUBLESHOOTING WARNING CAUTION When servicing or repairing this equipment, use only factoryapproved service replacement parts. A complete replacement parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owner’s risk.
PAGE 29
SERVICE & TROUBLESHOOTING Table 29.1 Troubleshooting Trouble Pilot does not light Possible Cause Possible Remedy 1. 2. 3. 4. Main gas is off. Power supply is off. Air in gas line. Dirt in pilot orifice. 1. 2. 3. 4. 5. Gas pressure out of proper range. 5. 6. 6. 8. Pilot valve does not open. a. Defective ignition controller. b. Defective gas valve. No Spark at ignitor. a. Loose wire connections. b. Pilot sensor is grounded. c. Defective ignition controller. Safety device has cut power. 9.
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SERVICE & TROUBLESHOOTING Trouble Possible Cause Possible Remedy Flashback 1. 2. 3. Too much primary air Main pressure set too high. Orifice too large. 1. 2. 3. Floating Flames (See Figure 30.3) 1. 2. 3. Insufficient primary air. Main pressure set too high. Orifice too large. 1. 2. 3. 4. Blocked vent. 4. 1. 2. Main pressure set too high. Orifice too large. 1. 2. 3. Blocked vent. 3. 1. Unit cycling on high limit. ➀ a. Obstructions/leaks in duct system. b. Main pressure set too high. c.
PAGE 31
RATING PLATE IDENTIFICATION Figure 31.1 - Serial Number Designations Figure 31.2 - Model Number Designations 01 12 101 10 97 MOTOR SUPPLIER CODE 01 Century 05 Universal etc. FAN OR BLOWER SUPPLIER CODE 01 Revcor 08 Brookside etc. SERIES IDENTITY NUMBER Identifies which series of controls were furnished on the unit. PD YEAR OF MANUFACTURE 97 1997 98 1998 etc. WEEK OF MANUFACTURE 10 10th week of 1997 25 25th week of 1997 etc.
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WARRANTY Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed.