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Modine Manufacturing PD User Manual

Modine Manufacturing PD
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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.
2.
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.
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Modine Manufacturing PD Specifications

General IconGeneral
BrandModine Manufacturing
ModelPD
CategoryGas Heater
LanguageEnglish

Summary

Critical Safety Information

Installation Hazards and Precautions

Covers risks from improper installation, corrosive vapors, and flammable liquids.

Gas Leak and Safety Procedures

Actions to take if a gas leak is detected and general safety advice.

Manual Usage and Initial Inspection

Guidance for qualified personnel and steps for unit inspection upon arrival.

Special Precautions for Safe Operation

Hazard Level Definitions

Explains DANGER, WARNING, CAUTION, and IMPORTANT designations.

Installation and Electrical Safety

Covers venting, electrical connections, wiring, gas pressure, and voltage requirements.

Operational and Environmental Risks

Addresses risks like corrosive vapors, improper ducting, and wet controllers.

Unit Location and Clearances

Location Recommendations

Guidance on selecting a safe and suitable location for unit installation.

Combustible Material Clearances

Specifies minimum distances to combustible materials for safe unit placement.

Combustion Air Requirements

Details requirements for providing adequate combustion air to the unit.

Unit Placement and Mounting

Sound and Vibration Considerations

Guidelines for minimizing noise and vibration transmission from the unit.

Unit Lifting Procedures

Instructions for safely lifting and handling the unit during installation.

Unit Suspension Methods

Detailed steps for securely suspending the unit using threaded rods or pipe adapters.

Venting Installation Requirements

General Venting Guidelines

Instructions for installing vents according to codes and specific site conditions.

Venting Safety Warnings

Critical warnings about operating unvented, blocked vents, and using approved exhausters.

ANSI Venting Requirements

Specifies requirements based on appliance category (I, II, III, IV).

Venting Termination and Common Venting

Minimum Roof Height for Venting

Table provides minimum vent height from roof based on roof pitch.

Category II Venting Requirements

Provides requirements for condensate drainage and vent system cleaning.

Common Venting Procedures

Guidelines for connecting to existing chimneys or common vents for Category III/IV units.

Gas Connection and Piping

Gas Connection Safety

Warnings about leak testing, gas pressure limits, and purging procedures.

Gas Piping Installation

Guidelines for installing gas piping, including code compliance and pipe sizing.

Sediment Trap and Shut-off Valve

Details on installing a sediment trap and manual shut-off valve for safety.

Electrical Connection Procedures

Electrical Connection Safety

Warnings about disconnecting power, correct wiring, wire ratings, and voltage.

Wiring and Grounding Compliance

Instructions for wiring installation, grounding, and component connections.

Power Supply Requirements

Details on voltage, phase balance, protection, and external service connections.

Ductwork and Blower Speed Adjustment

Ductwork Installation Guidelines

Practices for uniform air distribution, access panels, and blower enclosure kits.

Determining Blower Speed

How to adjust blower speed based on airflow and external static pressure.

Propeller Model Duct Restriction

Important note: Do not attach ductwork of any kind to propeller models.

Blower Assembly and Adjustments

Blower Assembly Installation

Steps for installing and connecting the blower assembly and motor.

Blower Speed Adjustment

Procedure for adjusting motor sheave for proper blower speed and performance.

Belt Tension and Alignment Check

Ensuring correct belt tension and sheave alignment for optimal blower operation.

Unit Start-Up Procedure

Pre-Start Checks

Ensuring proper power, wiring, venting, and mechanical checks before initial startup.

Operational Checks

Verifying electrical operation, blower rotation, motor performance, and gas supply.

Pilot Burner Adjustment

Procedure for adjusting the pilot flame for proper ignition and operation.

Main Burner and Flame Adjustment

Manifold Pressure Adjustment

Steps to adjust manifold pressure for proper gas input to the burners.

Natural Gas Flame Control

Procedure for adjusting primary air for optimal flame on natural gas.

Propane Gas Flame Control

Procedure for adjusting air shutters and manifold for optimal flame on propane.

Control Operating Sequences

Standing Pilot Systems

Describes operation for single-stage and two-stage standing pilot controls.

Intermittent Pilot Systems

Describes operation for single-stage and two-stage intermittent pilot controls.

Advanced Control Sequences

Two-Stage Gas Control Operation

Details operation for two-stage standing and intermittent pilot systems.

Mechanical Modulating Controls

Explains operation of mechanical modulating gas controls with automatic pilot ignition.

Factory Mounted Options

Gas Valve and Ignition Controller

Description of single-stage, two-stage, and modulating gas valves and ignition controllers.

Time Delay Relay and Terminal Board

Details on the time delay relay and low voltage terminal board for wiring connections.

Optional Unit Features

Control and Safety Options

Describes step-down transformers, high limit switches, and blocked vent safety switches.

Venting and Motor Options

Covers vent pipe connections and optional blower motor configurations.

Blower Model Performance Data

Performance Tables

Detailed performance data for blower models under various conditions.

Motor and Power Requirements

Information on motor specifications and power requirements for blower units.

Blower Performance with Filters and Options

Performance with Filters

Performance data when using external filters with blower units.

575V Ordering Notes

Important considerations for ordering 575V units and related transformers.

Nozzle Performance Data

Nozzle Types and Dimensions

Details on 40° downward, 90° vertical, 40° splitter, and 5-way nozzles.

Mounting Height and Heat Spread

Data on mounting height, heat throw, and heat spread for various nozzle types.

Propeller Hood Performance Data

30° Downward Deflector Hoods

Performance data for 30° downward deflector hoods for propeller units.

60° Downward Deflector Hoods

Performance data for 60° downward deflector hoods for propeller units.

90° Downward Deflector Hoods

Performance data for 90° downward deflector hoods for propeller units.

Blower Hood Performance Data

30° Downward Hoods for Blowers

Performance data for 30° downward deflector hoods on blower units.

60° Downward Hoods for Blowers

Performance data for 60° downward deflector hoods on blower units.

90° Downward Hoods for Blowers

Performance data for 90° downward deflector hoods on blower units.

Propeller Unit Dimensional Data

PD Model Dimensions

Table of dimensions for PD models, including overall size and connection points.

Mounting and Gas Connection Dimensions

Specifics on mounting hole sizes and gas connection sizes for PD units.

Blower Unit Dimensional Data

BD Model Dimensions

Table of dimensions for BD models, including overall size and connection points.

Mounting and Enclosure Dimensions

Specifics on mounting holes, blower enclosure, and gas connections for BD units.

Unit Maintenance Procedures

General Unit Cleaning and Inspection

Routine checks for dust, dirt, heat exchanger condition, wiring, and gas controls.

Component Assembly Removal

Step-by-step instructions for removing manifold and burner/pilot assemblies.

Troubleshooting Blocked Vent Safety Switch

BVSS Troubleshooting Flow Chart

Flowchart to diagnose and resolve issues related to the Blocked Vent Safety Switch.

Spillage and Negative Pressure Notes

Explanations of spillage determination and indications of negative space pressure.

Common Troubleshooting Issues

Pilot and Main Burner Ignition

Troubleshooting causes and remedies for pilot or main burner ignition failure.

Flame Appearance Problems

Addresses issues like lifting flames, yellow tipping, and wavering flames.

Advanced Troubleshooting and Limit Switches

Burner Performance Issues

Troubleshooting flashback, floating flames, flame rollout, and heat output problems.

Automatic Reset High Limit Switch

Explanation of the high limit switch function and troubleshooting when it trips.

Unit Identification and Parts

Serial and Model Number Breakdown

Explanation of designations for serial numbers and model numbers.

Rating Plate Information

Details found on the unit's serial plate, including specifications and approvals.

Product Warranty Information

General Warranty Terms

Seller's warranty limitations and exclusions for material and workmanship.

Component Specific Warranties

Details warranty periods for heat exchangers, burners, and other components.

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