Installation and Service Manual

ManualsBrandsModine ManualsCooling & Air QualityBDP Blower 300,000 BTU Non-Separated Aluminized Steel Heat Exchanger - LP

6-580.12

5H0782130000

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 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

Gas Connections ................................ 10

High-Altitude Accessory Kit .........................11

Electrical ...................................... 13

Start-Up Procedure/Operation ........................ 15

Unit Components .................................. 18

Performance Data - General ......................... 19

Performance Data - Downturn Hoods .................. 22

Dimensions....................................... 24

Service/Troubleshooting............................. 26

Serial/Model Number Designations . . . . . . . . . . . . . . . . . . . 29

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

INSTALLATION AND SERVICE MANUAL

power vented gas-fired unit heaters

models PDP and BDP

All models approved for use in California by the CEC and

in Massachusetts. Unit heater is certified for non-residential

applications.

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

The use and storage of gasoline or other

flammable vapors and liquids in open containers

in the vicinity of this appliance is hazardous.

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.

ARNING

IMPOR

ANT

May, 2017

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.

Summary of content (32 pages)

PAGE 1
6-580.12 5H0782130000 May, 2017 INSTALLATION AND SERVICE MANUAL power vented gas-fired unit heaters models PDP and BDP 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. WARNING 1.
PAGE 2
SPECIAL PRECAUTIONS WARNING 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. 12.
PAGE 3
SPECIAL PRECAUTIONS / SI (METRIC) CONVERSION FACTORS BEFORE YOU BEGIN CAUTION 15. 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. 16. 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). 17.
PAGE 4
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION UNIT LOCATION DANGER Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere. 9. Do not install units in locations where gas ignition system is exposed to water spray, rain, or dripping water. 10. Do not install units below 7', measured from the bottom of the unit to the floor, unless properly guarded to provide protection from moving parts. Figure 4.
PAGE 5
INSTALLATION UNIT MOUNTING 1. B e sure the means of suspension is adequate to support the weight of the unit (see pages 24 and 25 for unit weights). Figure 5.1 - Adjustable Mounting Brackets - To Adjust: 2. F or proper operation and to assure that flames are directed into the center of the heat exchanger tubes, the unit must be installed in a level horizontal position. Use a spirit level to ensure that the unit is suspended correctly. 1. Remove outer side panels. 2.
PAGE 6
INSTALLATION - VENTING WARNING 1. G as 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.
PAGE 7
INSTALLATION - VENTING A10. W hen 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.
PAGE 8
INSTALLATION - VENTING Figure 8.1 - Vertical Category I Vent System Section B – Vertical Vent System Installation B1. This section applies to vertically vented Category I vent systems and is in addition to “Section A – General Instructions – All Units”. B2. Vertical vent systems terminate vertically and must be sized in accordance with the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest edition. B3.
PAGE 9
INSTALLATION - VENTING Section C – Horizontal, Category III Vent System Installation Figure 9.2 - Horizontal Venting C1. This section applies to horizontally vented Category III vent systems and is in addition to “Section A – General Instructions – All Units”. C2. Horizontal vent systems terminate horizontally (sideways). C3. 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.
PAGE 10
INSTALLATION GAS CONNECTIONS WARNING Figure 10.1 - Recommended Sediment Trap/Manual Shut-off Valve Installation for Gas Connection 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.
PAGE 11
INSTALLATION - HIGH ALTITUDE ACCESSORY KIT HIGH ALTITUDE ACCESSORY KIT Manifold Pressure Adjustment 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'.
PAGE 12
INSTALLATION - HIGH ALTITUDE ACCESSORY KIT If the heating value of the gas being supplied is different than the values shown in Tables 11.1 and 11.2, use the following equation to determine the appropriate manifold pressure for the altitude and gas heating value being supplied. Equation 12.1 - Manifold Pressure for Derated Gas WHERE: MPACT BTUTBL BTUACT MPSL = Manifold Pressure (in. W.C.
PAGE 13
INSTALLATION ELECTRICAL CONNECTIONS DUCT INSTALLATION IMPORTANT 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 14
INSTALLATION rpm (see performance table for units with or without blower enclosure, page 20). See “Blower Adjustments” for setting of drive pulley turns open. If a blower unit is to be used with ductwork or nozzles, 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. Any device added externally to the unit, and which the air must pass through, causes a resistance to air flow called pressure loss.
PAGE 15
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 and furnace are in operation, check to be sure the blower has been set to the proper rpm for the application. Refer to page 14 for blower adjustments. 2. Start-up and adjustment procedures must be performed by a qualified service agency. 19. Open the field installed manual gas shut-off valve. 20.
PAGE 16
START-UP PROCEDURE Main Burner Adjustment The gas pressure regulator (integral to the combination gas control) is adjusted at the factory for average gas conditions. It is important that gas be supplied to the unit heater in accordance with the input rating on the serial plate. Actual input should be checked and necessary adjustments made after the unit heater is installed. Over-firing, a result of too high an input, reduces the life of the appliance and increases maintenance.
PAGE 17
START-UP PROCEDURE Control Operating Sequence All units are supplied with intermittent pilot systems with continuous retry control as standard. For intermittent pilot systems, both the main burner and pilot are turned off 100% when the thermostat is satisfied. For all units, the system will attempt to light the pilot for 70 seconds. If the pilot is not sensed, the ignition control will wait approximately 6 minutes with the combination gas control closed and no spark.
PAGE 18
UNIT AND CONTROL OPTIONS Figure 18.1 - Factory Mounted Option Location ➇ ⑥ ➁ ➆ ➄ ➂ ➀ ➃ 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. ➀ Gas Valve a) Single Stage Gas Valve - (STD) The main gas valve provides the pilot, regulator, main gas, and manual shutoff functions. For additional information, see the supplier literature included with the unit.
PAGE 19
GENERAL PERFORMANCE DATA Table 19.1 - Performance - Propeller (PDP) and Blower (BDP) Models ➀ ➁ Model Number PDP 150 PDP 175 PDP 200 PDP 250 PDP 300 PDP 350 PDP 400 BDP 150 BDP 175 BDP 200 BDP 250 BDP 300 BDP 350 BDP 400 Btu/Hr. Input ➀ 150,000 175,000 200,000 250,000 300,000 350,000 400,000 150,000 175,000 200,000 250,000 300,000 350,000 400,000 Btu/Hr.
PAGE 20
CFM 2778 2469 2222 2020 1852 1709 1587 3241 2881 2593 2357 2160 1994 1852 3704 3292 2963 2694 2469 2279 2116 4630 4115 3704 3367 3086 2849 2646 5556 4938 4444 4040 3704 3419 3175 6481 5761 5185 4714 4321 3989 3704 6584 5926 5387 4938 4558 4233 ATR 40 45 50 55 60 65 70 40 45 50 55 60 65 70 40 45 50 55 60 65 70 40 45 50 55 60 65 70 40 45 50 55 60 65 70 40 45 50 55 60 65 70 40 45 50 55 60 65 70 Model Size 20 150 175 200 250 300 6-580.
PAGE 21
GENERAL PERFORMANCE DATA Table 21.
PAGE 22
PERFORMANCE DATA - HOODS Table 22.
PAGE 23
PERFORMANCE DATA – NOZZLES Figure 23.1 - Mounting Height, Heat Throw, Heat Spread (in feet) 90° VERTICAL NOZZLE H H T S S 40° DOWNWARD NOZZLE S 5-WAY NOZZLES T H T S 40° SPLITTER NOZZLE S S Table 23.1 - Mounting Height, Heat Throw, Heat Spread (in feet) Model Number Nozzle Type 40° Downward Nozzle 90° Vertical Nozzle BDP 150 BDP 175 BDP 200 BDP 250 BDP 300 BDP 350 BDP 400 Max. Mounting Ht. (ft.) H 26 25 27 29 31 32 32 Heat Throw (ft.) T 79 76 81 86 94 96 96 Heat Spread (ft.
PAGE 24
DIMENSIONAL DATA Figure 24.1 - Dimensional Drawings - Propeller Units (Model PDP) M C A H F DD X W K AA G J K E B LL BB EE L (MIN. DISTANCE TO WALL) D (OPENING) Table 24.1 - Dimensions (inches) - PDP ➀ Dimension Symbol A B C D E F G H J K (Mounting Holes) ➂ L➃ M W X AA BB DD EE LL Gas Connections ➄ Fan Diameter Approx.
PAGE 25
DIMENSIONAL DATA Figure 25.1 - Dimensional Drawings - Blower Units (Model BDP) C A N F H W DD J K G AA E EE DD X S J O 5 9/16" P 5 9/16" G 3/4" K B QxV RxT BB D (OPENING) BLOWER FILTER RACK ENCLOSURE (OPTIONAL) (OPTIONAL) L (MIN. DISTANCE TO WALL) M (APPROX.) L (MIN. DISTANCE TO WALL) 4 7/8" Table 25.
PAGE 26
MAINTENANCE Gas Piping & Controls WARNING When servicing or repairing this equipment, use only factoryapproved 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 27
SERVICE & TROUBLESHOOTING Table 27.1 - Troubleshooting Trouble Pilot does not light Possible Cause 1. 2. 3. 4. Main gas is off. Power supply is off. Air in gas line. Dirt in pilot orifice. 5. Gas pressure out of proper range. 6. Pilot valve does not open. a. Defective ignition controller. b. Blown fuse on control board c. Defective gas valve. 7. No spark at ignitor. a. Loose wire connections. b. Pilot sensor is grounded. c. Blown fuse on control board d. Defective ignition controller. 8.
PAGE 28
SERVICE & TROUBLESHOOTING Trouble Possible Cause Not Enough Heat 1. Unit cycling on high limit. ➀ a. Obstructions/leaks in duct system. b. Main pressure set too high. c. Blower motor not energized. d. Loose belt e. Blower speed too low. f. Blocked/damaged venting system. g. Air distribution baffle removed (high temperature rise units only). h. Defective high limit switch. 2. Main pressure set too low. 3. Too much outside air. 4. Thermostat malfunction. 5. Gas controls wired incorrectly. 6.
PAGE 29
MODEL NUMBER / RATING PLATE IDENTIFICATION Figure 29.1 - Serial Number Designations S 01 10 09 17 09 23 09 1234 10000 Serial Number Prefix if standard “S” if Special Product Order SPO Number Number varies from 0000 to 9999.
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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.