Service manual

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THIS MANUAL IS THE PROPERTY OF THE OWNER.

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

Inspection on Arrival

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

immediately to the transportation company and your local

Modine sales representative.

Check rating plate on unit to verify that power supply meets

available electric power at the point of installation.

3. Inspect unit upon arrival for conformance with description of

product ordered (including specifications where applicable).

Table of Contents

Inspection on Arrival ................................. 1

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

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

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

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

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

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

Installation ........................................ 6

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

Venting & Condensate Drain ....................... 13

Gas Connections ................................ 14

High-Altitude Accessory Kit ........................ 15

Electrical Connections ............................ 17

Ductwork....................................... 18

Performance Data ................................. 20

Dimensions....................................... 26

Service/Troubleshooting............................. 28

Model/Serial Number/Replacement Parts ............... 31

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

INSTALLATION AND SERVICE MANUAL

high efficiency, separated combustion gas-fired unit heaters

models PTC and BTC

6-563.7

5H0807150000

November, 2014

Effinity

, Conservicore Technology, and any combination of

these names either together or with other words is trademarked

by Modine Manufacturing Co.

All models approved for use in California by the CEC and in

Massachusetts. Unit heater is certified for residential (size 110

and smaller only) and commercial applications.

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 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.

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.

Model PTC

Summary of content (32 pages)

PAGE 1
6-563.7 5H0807150000 November, 2014 Model PTC installation and service manual high efficiency, separated combustion gas-fired unit heaters models PTC and BTC All models approved for use in California by the CEC and in Massachusetts. Unit heater is certified for residential (size 110 and smaller only) and commercial applications. ® Effinity93, Conservicore Technology, and any combination of these names either together or with other words is trademarked by Modine Manufacturing Co.
PAGE 2
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.
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special precautions / SI (METRIC) CONVERSION FACTORS BEFORE YOU BEGIN CAUTION 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.
PAGE 4
unit location Figure 4.1 - Combustible Material and Service Clearances 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 temperatures between 40°F and 80°F. Heaters should not be used in applications where the heated space temperature is below 40°F.
PAGE 5
unit mOUNTING Alternate Suspension Methods CAUTION A pipe hanger adapter kit, 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 1-1/2" capscrews to facilitate threaded pipe suspension. Two kits would be required for PTC units and 3 kits for BTC units. 1.
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installation - venting A2. Model PTC/BTC units feature high thermal efficiency and are certified as Category IV vented appliances. The units will produce condensate during operation. Both the heater and the vent system must be connected to a condensate removal drain, which is detailed in this manual. A3. Vent pipe must be Schedule 40 PVC pipe. In Canada, all PVC vent pipe must be approved to ULC S636. The combustion air inlet pipe must be Schedule 40 PVC for model sizes 260 and smaller.
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installation - venting A12. For single wall galvanized combustion air inlet piping (model size 310 only), seal joints and seams with silicone sealant or 2 turns of metallic tape. Fasten individual lengths of vent together with at least 3 corrosion resistant sheet metal screws. A13. Do not install PVC pipe near high temperature sources of heat exceeding 140°F that could damage the pipe and cause hazardous leaks of products of combustion or water into the space. A14.
PAGE 8
installation - venting Section B - Vertical Vent System Installation B1. This section applies to vertically vented 2-pipe (1 combustion air inlet pipe and 1 vent pipe) and concentric (single roof penetration) vent systems and is in addition to “Section A General Instructions - All Units”. B2. Vertical vent systems terminate vertically (up). B3. It is required to install a tee with drip leg and clean out cap as shown in Figure 8.1. Please note the following requirements: a.
PAGE 9
installation - venting Figure 9.1 - Vertical 2-Pipe Vent System for Flat Roofs MODEL SIZES 55 THROUGH 260 24" Minimum from adjacent wall or building to Combustion Air Inlet Pipe Terminal 4.5" Minimum 4.
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installation - venting Section C - Horizontal Vent System Installation C1. This section applies to horizontally vented 2-pipe vent systems (1 combustion air inlet pipe and 1 vent pipe) and concentric (single wall penetration) and is in addition to “Section A - General Instructions - All Units”. C2. Horizontal vent systems terminate horizontally (sideways). C3. It is required to install a tee with drip leg and clean out cap as shown in Figure 10.1. Please note the following requirements: a.
PAGE 11
installation - venting Figure 11.
PAGE 12
installation - venting Section D - Concentric Vent System Installation CAUTION D1. This section applies to both horizontally and vertically vented concentric vent systems as defined in “Section A General Instructions - All Units”. The required instructions that must be followed are as follows: 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.
PAGE 13
installation - VENTING & CONDENSATE DRAIN Figure 13.1 - Adapter Box with Combustion Air Intake Pipe Attached Combustion Air Pipe Attached (See Dimension C) A B Combustion Air Intake Guard ➀ Model Size A B C 55-135 12.25" 14.63" 6" 156-260 13.39" 18.88" 6" 310 15.27" 17.00" 8" 4.57" ➀ For reference only for horizontal concentric vent arrangements. D11. Install the vent pipe by extending the vent pipe all the way through the concentric vent adapter assembly.
PAGE 14
installation - GAS CONNECTIONS GAS CONNECTIONS WARNING 1. 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. 2. 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. 3. Gas pressure to appliance controls must never exceed 14" W.C. (1/2 psi). 4.
PAGE 15
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 1,000' 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'.
PAGE 16
installation - HIGH ALTITUDE ACCESSORY KIT If the heating value of the gas being supplied is different than the values shown in Tables 15.1 and 15.2, use the following equation to determine the appropriate manifold pressure for the altitude and gas heating value being supplied. Equation 16.1 - Manifold Pressure for Derated Gas WHERE: MPACT = Manifold Pressure (in. W.C.) at Altitude – Manifold pressure setting for the heater being installed BTUTBL = BTU/ft3 Content of Gas – Obtained from Tables 15.
PAGE 17
installation - ELECTRICAL connections ELECTRICAL CONNECTIONS WARNING 1. D isconnect 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.
PAGE 18
installation WITH DUCTWORK Figure 18.1- Typical Duct & Airflow Installation Recommended Installations TURNING VANES 3" MIN. A B 3" MAX. 12" MIN. B 12" MIN. A A BAFFLE SIDE VIEW D TOP VIEW SIDE VIEW 12" MIN. E F 12" MIN. B B A TURNING VANES BAFFLE A BAFFLE SIDE VIEW SIDE VIEW IMPORTANT Do not attempt to attach ductwork of any kind to propeller models. When installing the heater, always follow good duct design practices for even distribution of the air across the heat exchanger.
PAGE 19
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 19.1 - Blower Model mounting brackets on blower assembly BLOWER SHEAVE Blower housing Following electrical connections, check blower rotation to assure blow-through heating.
PAGE 20
BLOWER performance data - MODEL BTC Table 20.
PAGE 21
BLOWER PERFORMANCE DATA - MODEL BTC Table 21.1 - Blower Model BTC215-310 - Model Size 0.
PAGE 22
installation - operation OPERATION Prior to Operation important Start-up and adjustment procedures must be performed by a qualified service agency. Although this unit has been assembled and fire-tested at the factory, the following pre-operational procedures should be performed to assure proper on-site operation. 1. Turn off power to the unit at the disconnect switch. Check that fuses or circuit breakers are in place and sized correctly. Turn all hand gas valves to the OFF position. 2.
PAGE 23
unit components Table 23.1 - Control Options Control Service Thermostat Type of Code No. Voltage Voltage Gas Control Description Single-Stage, Direct Spark Ignition, 100% Shut-Off with Continuous Retry Utilizes a single-stage combination gas control with ignition control. Gas is lit with a direct spark igniter on call for heat. 11 115V 24V Natural 21 115V 24V Propane Figure 23.
PAGE 24
GENERAL PERFORMANCE DATA - MODELS PTC & BTC Table 24.1 - Propeller Unit Heater Model PTC General Performance Data Model PTC Sizes 55 65 85 110 135 156 180 215 260 310 Btu/Hr Input ➀ 55,000 65,000 85,000 110,000 135,000 155,000 180,000 215,000 260,000 310,000 Btu/Hr Output ➀ 51,150 60,450 79,050 102,300 125,500 144,150 167,400 199,950 241,800 288,300 Condensate Production (Gal./Hr.) 0.3 0.4 0.5 0.7 1.0 1.1 1.3 1.6 1.9 2.
PAGE 25
PerformAnCe dATA - defleCTor Hoods figure 25.3 - 90° Hood Throw/floor Coverage figure 25.1 - 30°, 60°, & 90° deflector Hoods 30° HOOD 60° HOOD 90° HOOD H figure 25.2 - 30° & 60° Hood Throw/floor Coverage 30 DOWNTURN 60 DOWNTURN S 60 MOUNTING HEIGHT Table 25.2 - deflector Hood general Performance data - model PTC X 60 DOWNTURN Y X Z Y 30 DOWNTURN Z Note: X = Feet from Heater to Start of Floor Coverage Y = Feet to End of Floor Coverage Z = Feet to End of Throw Table 25.
PAGE 26
DIMENSIONAL DATA - MODEL PTC Figure 26.1 - Dimensional Drawings - Model PTC KNOCKOUTS FOR SUPPLY POWER WIRING CONDUIT ENTRANCE ADJUSTABLE LOUVERS Q (MINIMUM DISTANCE TO WALL) 3.56 14.90 A N (4) 3/8"-16 MTG HOLES P ACCESS PANEL M COMBUSTION AIR INLET E (OPENING) B VENT OUTLET GAS CONN. L K J FAN C F CONDENSATE DRAIN 3/4" PVC R (APPROX.) I G H D (OPENING) Table 26.1 - Dimensions (inches) - PTC ➀ Models PTC 55 PTC 65 PTC 85 PTC110 PTC135 PTC156 PTC180 PTC 215 PTC260 PTC310 A 29.
PAGE 27
DIMENSIONAL DATA - MODEL BTC Figure 27.1 - Dimensional Drawings - Model BTC BLOWER ENCLOSURE (OPTIONAL) 4.88 FILTER RACK (OPTIONAL) 7/8" (6) 3/8"-16 MTG HOLES ADJUSTABLE LOUVERS 3.56 V 14.90 A N W KNOCKOUTS FOR SUPPLY POWER WIRING CONDUIT ENTRANCE P X ACCESS PANEL M COMBUSTION AIR INLET TxU E (OPENING) VENT OUTLET B GAS CONN. L K J I C S CONDENSATE DRAIN 3/4" PVC R (APPROX.) Q (MIN DIST TO WALL) D (OPENING) F G H Table 27.
PAGE 28
service / maintenance / troubleshooting WARNING When servicing or repairing this equipment, use only factory-approved service replacement parts. A complete replacement parts list may be obtained by contacting the factory. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owner’s risk. CAUTION 1.
PAGE 29
service / maintenance / troubleshooting Table 29.1 - Troubleshooting TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Unit does nothing 1. Power supply is off 1. Turn on main power (verify green light on 2. No 24V power to thermostat 2 a. Check control transformer side of junction box b. If failed transformer - check thermostat wire gage and length is lit) 3. Thermostat malfunction 3 a. Verify wire connections to R&W terminals only b. Check / replace thermostat 4. LED flashes 4.
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page intentionally left blank 30 6-563.
PAGE 31
MODEL & SERIAL number / replacement parts Figure 31.
PAGE 32
commercial Warranty Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed.