Modine Manufacturing BSH Service manual

Modine Manufacturing BSH Service manual
5-571.4
5H76232A1
April, 2010
installation and service manual
gas-fired weatherproof duct furnaces
models HFG & HFP
Model HFG
us
c
9900100
FOR YOUR SAFETY
if you smell gas:
1. Don’t touch electrical switches.
2.Extinguish any open flame.
3.Immediately call your gas supplier.
Model HFP
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.
A qualified installation and service agency must
perform all installation and service of these
appliances.
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.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report it
immediately to transportation company and your local
factory 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).
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH the owner WHEN YOU LEAVE THE JOB.
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. 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. 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 dual rated units.
4. Disconnect power supply before making wiring
connections to prevent electrical shock and equipment
damage.
5. 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.
6. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
7. Ensure that the supply voltage to the appliance, as indicated
on the serial plate, is not 5% greater than rated voltage.
8. When servicing or repairing this equipment, use only
factory-approved 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.
caution
1. Appliances are designed for outdoor installation only. DO
NOT LOCATE APPLIANCES INDOORS.
2. 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 CAN/CGA-B149 codes.
3. Do not reuse any mechanical or electrical component which
has been wet. Such component must be replaced.
2
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, observe heat
exchanger tubes by looking at the heat exchanger through
field installed access openings in connecting ductwork. If
the bottom of the tubes become red while blower and duct
furnace are in operation, additional baffles must be inserted
between blower and duct furnace to assure uniform air flow
across the heat exchanger.
3. 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 than 5%.
4. To prevent premature heat exchanger failure, with all control
systems, a blower starting mechanism must be provided so
that the blower is running or energized within 45 seconds of
the gas control operation.
5. Start-up and adjustment procedures should be performed
by a qualified service agency.
6. To check most of the Possible Remedies in the
troubleshooting guide listed in Table 20.1, refer to the
applicable sections of the manual.
Table of Contents
Inspection on Arrival.................................................................. 1
General Information/Installation Codes..................................... 1
Special Precautions................................................................... 2
SI (Metric) Conversion Factors.................................................. 3
Unit Location.............................................................................. 3
Location Recommendations............................................... 3
Combustible Material and Service Clearances.................. 3
Unit Lifting.................................................................................. 4
Installation................................................................................. 4
Direction of Airflow.............................................................. 4
Duct Installation.................................................................. 4
Airflow Distribution.............................................................. 4
Venting............................................................................... 5
Gas Connections................................................................ 5
Electrical Connections........................................................ 7
Start-Up Procedure.................................................................... 7
Pilot Burner Adjustment...................................................... 8
Main Burner Adjustment..................................................... 8
Air Shutter Adjustment........................................................ 9
Control Operating Sequence............................................ 10
Variable Air Movement Applications................................. 11
Gas Control Options......................................................... 12
Dimensional Data............................................................... 13-14
Performance............................................................................ 15
Air Temperature and External Static Pressure Limits....... 15
Pressure Drop Curves........................................................ 16-17
Maintenance............................................................................ 18
Manifold Assembly Removal............................................ 18
Burner and Pilot Assembly Removal................................ 18
Service & Troubleshooting.................................................. 20-21
Automatic Reset High Limit.............................................. 20
Replacement Parts Ordering................................................... 22
Serial Plate Location........................................................ 22
Model Identification.................................................................. 23
Warranty.................................................................................. 24
5-571.4
si (metric) conversion factors / unit location
SI (Metric) Conversion Factors
Figure 3.1
Combustible Material and Service Clearances
Table 3.1
To ConvertMultiply ByTo Obtain
air flow
"W.C.
(inches water column)
0.24
kPa
6.893
kpa
subtract 32 and then multiply by 0.555
°C
inches
25.4
mm
feet
0.305
CFM
0.028
1.699
CFH
btu/ft3
meters
m3/min
m3/min
0.0374
mJ/m3
pound
0.453
kg
btu/hr
0.000293
kW/hr
27"
liters
➁
psig
°F
gallons
3.785
B
top view
B
nonaccess
side
danger
access
side
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
HFG
HFP
Unit Location
36"
a
c
➀
caution
Appliances are designed for outdoor installation only. DO NOT
LOCATE APPLIANCES INDOORS.
important
➀Minimum clearance to combustibles is 0.0'' from bottom of unit mounting rail or
3'' from bottom of sheet metal of unit casing.
➁Minimum clearance to combustible for HFP is 1.0'' from rooftop.
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 furnace, consider general space and heating
requirements and availability of gas and electrical supply.
2. Unit must be installed on the positive pressure side of the
circulating blower.
3. Be sure the structural support at the unit location site is
adequate to support the weight of the unit. 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. For HFG units, be sure clearances are
maintained to the combustion air/vent cap. For HFP units,
be sure clearances are maintained to the combustion air
inlet louvers and power exhauster discharge cover. Units
are designed for installation on non-combustible surfaces or
combustible surfaces with the minimum clearances shown in
Figure 3.1, Table 3.2, and Table 3.3.
5-571.4
Table 3.2
Combustible Material Clearances
Clearance to
Combustible Materials
ModelFrontFront
Non-AccessAccess
Size
& Rear (B) & Rear (B)Side (C)Side (A)
HFG
HFP
HFG/HFP HFG HFP
75
0"
3"
0"
0"
3"
100/125
0"
3"
0"
0"
3"
150/175
3"
3"
0"
0"
3"
200/225
4"
4"
0"
0"
3"
250/300
5"
5"
0"
0"
3"
350/400
11"
11"
0"
0"
3"
Table 3.3
Service Clearances
Recommended
Service
Clearance
ModelAccessNonSizeSideAccess
(A)Side (C)
75
18"
6"
100/125
20"
6"
150/175
25"
6"
200/225
27”
6”
250/300
30"
6"
350/400
41"
6"
3
unit lifting / installation
Unit Lifting
Lifting holes are provided in the mounting rails of the duct
furnace. When lifting the unit, use spreader bars between the
lifting cables as shown in Figure 4.1 to insure that no damage
will occur to the sheet metal parts of the duct furnace.
Figure 4.1 - Unit Lifting
Duct Installation
1. The furnace is designed to accept 90° flanged ductwork.
See Figure 4.3. Provide an airtight seal between the
ductwork and the furnace. Seams with cracks in ductwork
should be caulked and/or taped and be of permanent type.
All duct connections MUST be weathertight to prevent rain
and snow from entering the ductwork.
2. Provide removable access panels on both the upstream
and downstream sides of the ductwork; see Figure 4.3.
These openings should be large enough to view smoke or
reflect light inside the casing to indicate leaks in the heat
exchanger and to check for hot spots on heat exchangers
due to poor air distribution or lack of sufficient air (CFM).
Figure 4.3 - Duct Connections
1/2"
duct furnace
ductwor
Installation
k
Direction of Airflow
Select proper direction of airflow. If the unit is not provided with
an air distribution baffle (Not provided on models in which the
10th digit of the model number is an “L” for Low Temperature
Rise), the airflow direction is fully reversible without modification
to the duct furnace. See Airflow Reversal Note.
If the unit is provided with an air distribution baffle (Provided on
models in which the 10th digit of the model number is an “H”
for High Temperature Rise), the air baffle must face the air inlet
direction as shown in Figure 4.2. If it is necessary to reverse
the airflow direction, remove the four screws securing the air
distribution baffle, reverse the air distribution baffle to the air
inlet side and replace the screws. See Airflow Reversal Note.
Figure 4.2 - Air Distribution Baffle Location
Baffle location shown on entering air side of duct furnace.
air
distribution
baffle
90°
Flanged
ductwork
Airflow Distribution
important
To prevent premature heat exchanger failure, observe heat
exchanger tubes by looking at the heat exchanger through
field installed access openings in connecting ductwork. If
the bottom of the tubes become red while blower and duct
furnace are in operation, additional baffles must be inserted
between blower and duct furnace to assure uniform air flow
across the heat exchanger.
1. Provide uniform air distribution over the heat exchanger.
Use turning vanes where required (see Figure 5.1) to obtain
uniform air distribution. Avoid installing as in “G”, “H” & “J” of
Figure 5.1.
2. A bottom, horizontal discharge type blower should be
installed at least 12" from the furnace (See “A”, Figure 5.1).
3. A top, horizontal discharge type blower should be installed
at least 24" from the furnace (See “B”, Figure 5.1). Provide
air baffle at top of duct to deflect air down to the bottom of
heat exchanger.
Airflow Reversal Note: If factory installed discharge air
options (thermostat, freeze protection, etc.) were provided,
these options would have to be relocated to the discharge air
side of the duct furnace.
4
access
panel
5-571.4
installation
Figure 5.1 - Typical Duct & Airflow Installation
RECOMMENCED
INSTALLATIONS
RECOMMENDED
INSTALLATIONS
3" Max.
A
Turning
Vanes
3" Min.
12"
Min.
Turning
Vanes
B
12"
Min.
SIDE VIEW
A
Baffle
24"
Min.
SIDE VIEW
15° Max.
TOP VIEW
E
12"
Min.
Turning
Vanes
A
Baffle
F
Turning
Vanes
3" Max.
B
3" Max.
C
24"
Min.
SIDE VIEW
Air
Baffle
12"
Min.
A
Baffle
12"
Min.
B
A
D
B
Air
Baffle
3" Min.
B
3" Max.
B
Dimensions “B” should never
be less than 1¼2 of “A”.
12"
Min.
Turning
Vanes
3" Min.
Turning
Vanes
Turning
Vanes
15° Max.
SIDE VIEW
15° Max.
TOP VIEW
INSTALLATIONS NOT RECOMMENDED
G
POOR
No Air
SIDE VIEW
H
POOR
J
POOR
No Air
No Air
SIDE VIEW
TOP VIEW
Venting
Gas Connections
1. Installation of venting 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 CAN/
CGA-B149.1 for natural gas units and CAN/CGA-B149.2 for
propane units.
2. For HFG units, do not operate duct furnaces without the
factory supplied vent cap (shipped loose) fastened securely
in place. HFP units are shipped with the power exhauster
discharge cover factory installed.
3. For HFG units, do not modify or obstruct the vent cap
in any manner. For HFP units, do not modify or obstruct
the combustion air inlet louvers or the power exhauster
discharge cover.
4. Do not add any vents other than those supplied by the
manufacturer.
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 dual rated units.
caution
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 CAN/CGA-B149 codes.
IMPORTANT
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 than 5%.
5-571.4
5
installation
Gas Connections (continued)
5. When Pressure/Leak testing, pressures above 14" W.C.
(1/2 psi), close the field installed shut-off valve, disconnect
the appliance and its combination gas control from the gas
supply line, and plug the supply line before testing. When
testing pressures 14" W.C. (1/2 psi) or below, close the
manual shut-off valve on the appliance before testing.
1. Installation of piping 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 CAN/CGA-B149.1 for
natural gas units and CAN/CGA-B149.2 for propane units.
2. Piping to units should conform with local and national
requirements for type and volume of gas handled, and
pressure drop allowed in the line. Refer to Table 9.1 to
determine the cubic feet per hour (cfh) for the type of gas
and size of unit to be installed. Using this cfh value and the
length of pipe necessary, determine the pipe diameter from
Table 6.1. Where several units are served by the same main, the total capacity, cfh and length of main must be
considered. Avoid pipe sizes smaller than 1/2". Table 6.1
allows for a 0.3" W.C. pressure drop in the supply pressure
from the building main to the unit. The inlet pressure to the
unit must be 6-7" W.C. for natural gas and 11-14" W.C. for
propane gas. When sizing the inlet gas pipe diameter, make
sure that the unit supply pressure can be met after the 0.3"
W.C. has been subtracted. If the 0.3" W.C. pressure drop is
too high, refer to the Gas Engineer’s Handbook for other gas
pipe capacities.
3. The gas piping to the unit can enter the unit from the side
of the unit or from below (curb mounted units). Drill locator
dimples are located in the side and bottom of the unit for
field drilling the hole for the gas pipe entry.
Figure 6.1
Recommended Sediment Trap/Manual Shut-off Valve
Installation - Side Gas Connection
GAS
SUPPLY LINE
➀
GAS
SUPPLY LINE
TO
CONTROLS
PLUGGED
1/8" NPT TEST
GAGE CONNECTION
3"
MIN.
SEDIMENT
TRAP
Figure 6.2
Recommended Sediment Trap/Manual Shut-off Valve
Installation - Bottom Gas Connection
For side piped units
MANUAL GAS
SHUT-OFF VALVE
GROUND
JOINT
UNION
W/ BRASS
SEAT
Install a ground joint union with brass seat and a manual
shut-off valve external of the unit casing, and adjacent to the
unit for emergency shut-off and easy servicing of controls,
including a 1/8" NPT plugged tapping accessible for test
gauge connection (See Figure 6.1).
TO
CONTROLS
PLUGGED 1/8"
NPT TEST GAGE
CONNECTION
For bottom piped units
Install a ground joint union with brass seat and a manual
shut-off valve internal to the unit casing for easy servicing of
controls, including a 1/8" NPT plugged tapping accessible for
test gauge connection (See Figure 6.2). Note: Some local
codes may require a manual shutoff valve external to the unit
casing. In this case, the gas piping must exit the unit through
a side piping hole, followed by the manual shut-off valve,
piped back into the unit corner post, through the unit bottom,
and lead to an additional union and manual shut-off valve.
4. Provide a sediment trap before each unit in the line where
low spots cannot be avoided. (See Figures 6.1 & 6.2).
Through hole
in bottom of unit.
(caulk hole to prevent
water leakage.)
➀
GAS
SUPPLY LINE
MANUAL GAS
SHUT-OFF VALVE
GROUND
JOINT
UNION
W/ BRASS
SEAT
3"
MIN.
SEDIMENT
TRAP
➀ Manual shut-off valve is in the “OFF” position when handle is perpendicular to
pipe.
Table 6.1 - Gas Pipe Capacities
Gas Pipe Capacities (Up to 14” W.C. Gas Pressure through Schedule 40 Pipe)
Cubic Feet per Hour with Pressure Drop of 0.3” W.C.
Natural Gas - Specific Gravity - 0.60
Propane Gas - Specific Gravity - 1.50
Length Pipe Diameter
Of Pipe
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
(feet)Natural PropaneNatural PropaneNatural PropaneNatural PropaneNatural PropaneNatural Propane
10
132
83
278
175
520
328
1050
662
1600
1008
3050
1922
20
92
58
190
120
350
221
730
460
1100
693
2100
1323
30
73
46
152
96
285
180
590
372
890
561
1650
1040
40
63
40
130
82
245
154
500
315
760
479
1450
914
50
56
35
115
72
215
135
440
277
670
422
1270
800
60
50
32
105
66
195
123
400
252
610
384
1150
725
70
46
29
96
60
180
113
370
233
560
353
1050
662
80
43
27
90
57
170
107
350
221
530
334
990
624
90
40
25
84
53
160
101
320
202
490
309
930
586
100
38
24
79
50
150
95
305
192
460
290
870
548
125
34
21
72
45
130
82
275
173
410
258
780
491
150
31
20
64
40
120
76
250
158
380
239
710
447
6
5-571.4
installation / START-UP PROCEDURE
Electrical Connections
Start-Up Procedure
warning
important
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. Ensure that the supply voltage to the appliance, as indicated
on the serial plate, is not 5% greater than rated voltage.
1. Installation of wiring must conform with local building
codes, or in the absence of local codes, with the National
Electric Code ANSI/NFPA 70 - Latest Edition. Unit must
be electrically grounded in conformance to this code.
In Canada, wiring must comply with CSA C22.1, Part 1,
Electrical Code.
2. All duct furnaces are provided with a wiring diagram located
on the inside door of the electrical junction box. Refer to
this wiring diagram for all wiring connections. For factory
installed options and field installed accessory wiring, refer to
Set A and Set B on the provided wiring diagram.
3. The power supply to the duct furnace should be protected
with a fused disconnect switch.
4. Refer to Table 7.1 to determine the amp draw of the duct
furnace. Size the disconnect switch to cover the amp draw
of the unit.
5. Refer to the unit dimensional drawings on pages 13 and 14
for the location of the drill locator dimples in the side and
bottom of the unit for field drilling the hole for the electrical
conduit entry.
Table 7.1 - Unit Amps
Transformer (Digit 15)
Base Model Supply
Voltage
(Digits 1-6)
(Digit 14)
A
B or D
HFG (All)
C or E
F
G
A
B or D
HFP
C or E
75-175
F
G
A
B or D
HFP
C or E
200-400
F
G
1
0.35
0.19
0.17
0.09
0.07
1.75
0.89
0.83
0.63➀
0.50➀
2.35
1.14
1.27
0.63➀
0.50➀
2
0.65
0.36
0.33
0.16
0.13
2.05
1.06
0.99
1.25➁
1.00➁
2.65
1.31
1.43
1.25➁
1.00➁
3
1.30
0.72
0.65
0.33
0.26
2.70
1.42
1.31
2.50➂
2.00➂
3.30
1.67
1.75
2.50➂
2.00➂
4
2.17
1.20
1.09
0.54
0.43
3.57
1.90
1.75
2.72➂
2.17➂
4.17
2.15
2.19
2.72➂
2.17➂
0
0.00
0.00
0.00
0.00
0.00
1.40
0.70
0.66
0.00➃
0.00➃
2.00
0.95
1.10
0.00➃
0.00➃
Start-up and adjustment procedures should be performed by a
qualified service agency.
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. Check that the supply voltage matches the unit supply
voltage listed on the serial plate. Verify that all wiring is
secure and properly protected. Trace circuits to insure that
the unit has been wired according to the wiring diagram.
3. Check that all electrical and gas connections are
weatherized.
4. For HFG units, check to insure that the vent cap is installed
and free from obstructions. For HFP units, check to
insure that the combustion air inlet louvers and the power
exhauster discharge cover is free from obstructions/damage.
5. Check to see that there are no obstructions to the intake
and discharge of the duct furnace.
6. Perform a visual inspection of the unit to make sure no
damage has occurred during installation.
7. Turn on power to the unit at the disconnect switch. Check to
insure that the voltage between terminals 1 and 2 is 24V.
8. Check the thermostat, ignition control, gas valve, and supply
fan blower motor for electrical operation. If these do not
function, recheck the wiring diagram. Check to insure that
none of the Gas Control Options & Accessories (see page
12) have tripped.
9. Recheck the gas supply pressure at the field installed
manual-shut-off valve. The inlet pressure should be 6" - 7"
W.C. on natural gas or 11" - 14" W.C. on propane. If inlet
pressure is too high, install an additional pressure regulator
upstream of the combination gas control.
10.Open the field installed manual gas shut-off valve.
11.Open the manual main gas valve on the combination gas
control. Call for heat with the thermostat and allow the
pilot to light. (For HFP units, on a call for heat the power
exhauster relay will energize the power exhauster motor.
Once the power exhauster motor reaches full speed, a
centrifugal switch in the motor will close before the pilot can
light.) If the pilot does not light, purge the pilot line. If air
purging is required, disconnect the pilot line at outlet of pilot
valve. In no case should line be purged into heat exchanger.
Check the pilot flame length (See Pilot Burner Adjustment).
12.Once the pilot has been established, check to make sure
that the main gas valve opens. Check the manifold gas
pressure (See Main Burner Adjustment) and flame length
(See Air Shutter Adjustment) while the circulating air blower
is operating.
13.Check to insure that gas controls sequence properly
(See Control Operating Sequence). Verify if the unit has
any additional control devices and set according to the
instructions in the Gas Controls Options.
14.Once proper operation of the duct furnace has been
verified, remove any jumper wires that were required for
testing.
15.Close the electrical compartment door.
16.Replace all exterior panels.
➀ Includes a field supplied 250 VA step down transformer from supply voltage to 115V.
➁ Includes a field supplied 500 VA step down transformer from supply voltage to 115V.
➂ Includes a field supplied 1000 VA step down transformer from supply voltage to 115V.
➃ Unit amp draw is included in master unit amp draw.
5-571.4
7
START-UP PROCEDURE
Pilot Burner Adjustment
To Adjust the Manifold Pressure
The pilot burner is orificed to burn properly with an inlet
pressure of 6-7" W.C. on natural gas and 11-14" W.C. on
propane gas, but final adjustment must be made after
installation. If the pilot flame is too long or large, it is possible
that it may cause soot and/or impinge on the heat exchanger
causing failure. If the pilot flame is shorter than shown, it may
cause poor ignition and result in the controls not opening the
combination gas control. A short flame can be caused by a
dirty pilot orifice. Pilot flame condition should be observed
periodically to assure trouble-free operation.
1. Move the field installed manual shut-off valve to the “OFF”
position.
2. Remove the 1/8" pipe plug in the pipe tee and attach a
water manometer of “U” tube type which is at least 12" high.
3. Move the field installed manual gas shut-off valve to the
“ON” position.
4. Create a high fire call for heat from the thermostat.
5. Determine the correct high fire manifold pressure. For
natural gas 3.5” W.C., for propane gas 10” W.C. Adjust the
main gas pressure regulator spring to achieve the proper
manifold pressure (for location, see the combination gas
control literature supplied with unit).
6. If the unit has Electronic Modulation gas controls
(determine from the Model Identification Digit 12), the low
fire gas pressure needs to be adjusted. Using Figure 9.2 for
item number locations, this is accomplished as follows:
a. Disconnect power.
b. Remove all wires from duct furnace terminal “43” and
remove cover plate (2).
c. Turn on power at the disconnect switch.
d. Remove the maximum adjustment screw (4), spring
(5), and plunger (8). A small magnet is useful for this
purpose. CAUTION - The plunger is a precision part.
Handle carefully to avoid marring or picking up grease
and dirt. Do not lubricate.
e. Using minimum adjusting screw (9), adjust low fire
manifold pressure to 0.56" W.C. for natural gas and 1.6" W.C. for propane gas.
f. Replace plunger and spring retainer, spring, and
maximum adjusting screw in proper order.
g. Using maximum adjustment screw (4), adjust high fire
manifold pressure to 3.5" W.C. for natural gas and 10"
W.C. for propane gas.
h. Disconnect power.
i. Replace cover plate (2) and re-install all wires from
duct furnace terminal “43”.
7. After adjustment, move the field installed manual shut-off
valve to the “OFF” position and replace the 1/8" pipe plug.
8. After the plug is in place, move the field installed manual
shut-off valve to the “ON” position and recheck pipe plugs
for gas leaks with soap solution.
To Adjust the Pilot Flame
1. Create a call for heat from the thermostat.
2. Remove the cap from the pilot adjustment screw. For
location, see the combination gas control literature supplied
with unit.
3. Adjust the pilot length by turning the screw in or out
to achieve a soft steady flame 3/4" to 1" long and
encompassing 3/8"-1/2" of the tip of the thermocouple or
flame sensing rod (See Figure 8.1).
4. Replace the cap from the pilot adjustment screw.
Figure 8.1 - Correct Pilot Flame
3/4" to 1"
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 duct furnace in
accordance with the input rating on the serial plate. Actual
input should be checked and necessary adjustments made
after the duct furnace is installed. Over-firing, a result of too
high an input, reduces the life of the appliance and increases
maintenance. Under no circumstances should the input exceed
that shown on the serial plate.
Measuring the manifold pressure is done at the tee in the
manifold (See Figure 9.1).
8
5-571.4
start-up procedure
Figure 9.1
Checking Manifold Pressure with “U” Tube Manometer
Air Shutter Adjustment
Proper operation provides a soft blue flame with a well-defined
inner core. A lack of primary air will reveal soft yellow-tipped
flames. Excess primary air produces short, well-defined flames
with a tendency to lift off the burner ports. For both natural
and propane gas, the air shutters can be adjusted to control
the burner flame height. The air shutters can be accessed
by reaching behind the manifold tee shown in Figure 9.1. The
larger models may require the removal of the manifold (see
Manifold Assembly Removal).
Natural Gas Flame Control
Control of burner flames on duct furnaces utilizing natural gas
is achieved by resetting the primary air shutters (See Figure
19.1) to either increase or decrease primary combustion air.
Prior to flame adjustment, operate duct furnace for about fifteen
minutes. The main burner flame can be viewed after loosening
and pushing aside the gas designation disc on the side of the
burner box.
To increase primary air, loosen the air shutter set screws and
move the air shutters closer to the manifold until the yellowtipped flames disappear. (See Figure 19.1 for air shutter and
heat exchanger support locations.) To decrease primary air,
move the air shutters away from the manifolds until flames no
longer lift from burner ports, but being careful not to cause
yellow tipping. Retighten set screws after adjustment.
manifold tee
Propane Gas Flame Control
Figure 9.2
Maxitrol Modulating Valve Adjustments
An optimum flame will show a slight yellow tip. Prior to flame
adjustment, operate furnace for at least fifteen minutes. Loosen
air shutter set screws and move the air shutters away from the
manifold to reduce the primary air until the yellow flame tips
appear. Then increase the primary air until yellow tips diminish
and a clean blue flame with a well defined inner cone appears.
Table 9.1
Manifold Pressure and Gas Consumption
Model SizeType of GasNatural
Btu/Cu. Ft.
1040
Specific Gravity
0.60
Propane
2500
1.53
High Fire Manifold Pressure No. of
Inches of Water Column
3.5
10Orifices
5-571.4
75
100
125
150
175
200
225
250
300
350
400
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
Cfh
Orifice Drill Size
72.1
20
96.1
30
120.2
25
144.2
30
168.3
27
192.3
23
216.3
20
240.4
25
288.7
20
336.5
27
384.6
23
30.0
37
40.0
45
50.0
42
60.0
45
70.0
43
80.0
40
90.0
37
100.0
42
120.0
37
140.0
43
160.0
40
1
2
2
3
3
3
3
4
4
6
6
9
start-up procedure
important
To prevent premature heat exchanger failure, with all control
systems, a blower starting mechanism must be provided so
that the blower is running or energized within 45 seconds of
the gas control operation.
Control Operating Sequence
All Modine weatherproof duct furnaces are supplied with
intermittent pilot ignition systems. These systems are offered
with 100% shut-off with continuous retry for operation on
natural gas and 100% shut-off with lockout for units operating
on propane gas. On all systems, both the main burner and pilot
burner are turned off 100% when the thermostat is satisfied.
For natural gas units, the ignition controller is 100% shut-off
with continuous retry. On a call for heat, the system will attempt
to light the pilot for 70 seconds. If the pilot is not sensed for
any reason, the ignition control will wait for approximately six
minutes with the combination gas control closed and no spark.
After six minutes, the cycle will begin again. After three cycles,
some ignition controllers lockout for approximately one hour
before the cycle begins again. This will continue indefinitely until
the pilot flame is sensed or power is interrupted to the system.
For propane gas units, the ignition controller is 100% shut-off
with lockout. On a call for heat, the system will attempt to light
the pilot for 70 seconds. If the pilot is not sensed for any reason,
the ignition control will lockout, the pilot gas valve shut off and
the sparking discontinued. The system will not attempt to relight
until power has been interrupted to the controls and the controls
are reset via the thermostat.
Note: Gas Control Options (see page 12) could change the
listed sequence of operation based on their function.
The descriptions given are for the basic duct furnace.
Single-Stage Gas Controls
Utilizes a single-stage combination gas control, an ignition
control, and a single-stage low voltage thermostat.
1. The thermostat calls for heat. For HFP units, see ➀.
2. The pilot valve opens and the spark ignitor sparks in an
attempt to light the pilot. (If the unit was not provided with a
time delay relay, the blower starts at this time.)
3. Once the pilot is lit, the flame sensor proves the pilot and
stops the spark ignitor from sparking.
4. The main gas valve is opened and the main burner is lit to
100% full fire.
5. If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
6. The unit continues to operate until the thermostat is
satisfied, at which time both the main and pilot valves close
100%. (If the unit was not provided with a time delay relay,
the blower stops at this time.)
7. If the unit was provided with a time delay relay, the blower
stops after 30 to 45 seconds.
Two-Stage Gas Controls
Utilizes a two-stage combination gas control, an ignition control,
and a two-stage low voltage thermostat. The unit fires at 50%
fire on low stage and 100% fire on high stage.
1. The thermostat calls for low stage heat. For HFP units, see ➀.
2. The pilot valve opens and the spark ignitor sparks in an
attempt to light the pilot. (If the unit was not provided with a
time delay relay, the blower starts at this time.)
3. Once the pilot is lit, the flame sensor proves the pilot and
stops the spark ignitor from sparking.
4. The main gas valve is opened and the main burner is lit to
50% fire.
5. If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
6. If the temperature at the thermostat continues to fall, the
thermostat will call for high stage heat.
7. The main gas valve is opened completely and the main
burner is lit to 100% full fire.
8. The unit continues to operate until the high stage of the
thermostat is satisfied, at which time the main valve closes
to 50% fire.
9. The unit continues to operate until the low stage thermostat
is satisfied, at which time both the main and pilot valves
close 100%. (If the unit was not provided with a time delay
relay, the blower stops at this time.)
10. If the unit was provided with a time delay relay, the blower
stops after 30 to 45 seconds.
Electronic Modulating Gas Controls
Single Furnace
Utilizes an electronic modulating/regulating gas control,
combination gas valve, an ignition control, modulating amplifier,
and either a modulating room thermostat or modulating
duct thermostat with remote temperature set point adjuster.
The thermostat controls can modulate the gas flow between
40% through 100% full fire. When the thermostat is satisfied,
the amplifier cuts power to the combination gas valve which
prevents gas flow to both the main and pilot burners.
When duct sensing is utilized, a room override thermostat can
be added. When calling for heat, the room override thermostat
provides full fire operation until the space temperature is
satisfied. Control is then returned to the duct sensing control.
In this situation, either the duct sensor or the room override
thermostat can call for heat.
1. The thermostat calls for heat. For HFP units, see ➀.
2. The pilot valve opens and the spark ignitor sparks in an
attempt to light the pilot. (If the unit was not provided with a
time delay relay, the blower starts at this time.)
3. Once the pilot is lit, the flame sensor proves the pilot and
stops the spark ignitor from sparking.
4. The main gas valve is opened and the main burner is lit to
100% full fire.
5. If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
6. The modulating gas valve can be controlled by either
an electronic modulating room or duct thermostat. The
thermostat can modulate the firing rate between 40%
through 100% full fire. The call for heat is created by a
resistance signal (8000 to 12000 ohms) in the thermostat.
The amplifier converts this resistance into a DC voltage (0
to 12 volts DC with 0 volts high fire and 12 volts low fire).
The output voltage is applied to the modulating gas valve to
control the gas flow to the main burner. As the temperature
drops, the voltage drops causing the modulating valve to
open further. If the discharge air temperature increases,
the voltage increases causing the modulating valve to
close allowing less gas flow to the main burner. For further
information regarding the operation of the electronic
modulating system, consult the literature provided with the
unit.
7. The unit continues to operate in this manner until the
thermostat is satisfied, at which time both the main and
pilot valves close 100%. (If the unit was not provided with a
time delay relay, the blower stops at this time.)
8. If the unit was provided with a time delay relay, the blower
stops after 30 to 45 seconds.
➀ After the thermostat calls for heat, the power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the power
exhauster centrifugal switch closes energizing the gas control circuit.
10
5-571.4
start-up procedure
Electronic Modulating Gas Controls - Master/Slave
One Master furnace is provided with up to three Slave furnaces
that utilize electronic modulating/regulating gas controls,
combination gas valves, ignition controls, one multiple furnace
modulating amplifier, and either a modulating room thermostat
or modulating duct thermostat with remote temperature adjuster.
The thermostat controls can modulate the gas flow of all the
furnaces between 40% through 100% full fire. The amplifier
sends a signal to all of the gas valves so that they modulate
at the same percentage. When the thermostat is satisfied,
the amplifier cuts power to the combination gas valves which
prevents gas flow to both the main and pilot burners.
When duct sensing is utilized, a room override thermostat can
be added. When calling for heat, the room override thermostat
provides full fire operation until the space temperature is
satisfied. Control is then returned to the duct sensing control.
In this situation, either the duct sensor or the room override
thermostat can call for heat.
The sequence of operation for Electronic Modulating Gas
Controls - Master/Slave is the same as Electronic Modulating
Gas Controls - Single Furnace.
Electronic Modulating Gas Controls Building Management Control
(0-10Vdc or 4-20 mA Signal)
7. The unit continues to operate in this manner until the
thermostat is satisfied, at which time the BMS heat contact
opens resulting in both the main and pilot valves closing
100%. (If the unit was not provided with a time delay relay,
the blower stops at this time.)
8. If the unit was provided with a time delay relay, the blower
stops after 30 to 45 seconds.
Variable Air Movement Applications
When the air mover supplied by others can provide variable
air movement (i.e. 2-speed or variable frequency drive units),
the allowable minimum CFM of the HFG/HFP duct furnace can
be 66% of the minimum listed CFM in Table 15.2 if the unit is
applied as follows:
1. The unit is provided with 2-stage, mechanical modulation,
or electronic modulating gas controls. (see Model
Identification).
2. The unit is provided with a factory installed discharge air
controller.
3. The system does not include a room thermostat.
The factory installed discharge air thermostat will prevent the
unit from firing above the allowable 100°F rise when the unit is
at or above the minimum CFM by monitoring the discharge air
and going to low fire. A room thermostat, because it is located
remote from the unit, could cause the unit to over-fire.
Utilizes an electronic modulating/regulating gas control,
combination gas valve, an ignition control, modulating signal
conditioner, and an inverted (0 Vdc or 4mA being high fire and
10 Vdc or 20 mA being low fire) 0-10Vdc or 4-20 mA input
signal provided by a Building Management System (BMS). The
signal conditioner can modulate the gas flow between 40%
through 100% full fire. When the BMS thermostat (field supplied)
is satisfied, the BMS heat contact (field supplied) opens to cut
power to the combination gas valve which prevents gas flow to
both the main and pilot burners.
1. The BMS thermostat (field supplied) calls for heat and
closes the BMS heat contact (field supplied). For HFP units,
see ➀.
2. The pilot valve opens and the spark ignitor sparks in an
attempt to light the pilot. (If the unit was not provided with a
time delay relay, the blower starts at this time.)
3. Once the pilot is lit, the flame sensor proves the pilot and
stops the spark ignitor from sparking.
4. The main gas valve is opened and the main burner is lit to
100% full fire.
5. If the unit was provided with a time delay relay, the blower
starts after 30 to 45 seconds.
6. The modulating gas valve is controlled the BMS thermostat.
The thermostat can modulate the firing rate between
40% through 100% full fire by modulating the input signal
between either 0-10Vdc or 4-20 mA (The signal conditioner
can accept a 0-10 Vdc signal when all the dip switches are
in the “OFF” position and 4-20 mA signal when all the dip
switches are in the “ON” position). The signal conditioner
converts the input signal into a DC voltage (0 to 12 volts
DC with 0 volts high fire and 12 volts low fire). The output
voltage is applied to the modulating gas valve to control the
gas flow to the main burner. As the temperature drops, the
voltage drops causing the modulating valve to open further.
If the discharge air temperature increases, the voltage
increases causing the modulating valve to close allowing
less gas flow to the main burner. For further information
regarding the operation of the electronic modulating
system, consult the literature provided with the unit.
➀ After the thermostat calls for heat, the power exhauster relay is energized starting the power exhauster motor. Once the motor has reached full speed, the power
exhauster centrifugal switch closes energizing the gas control circuit.
5-571.4
11
start-up procedure
Gas Control Options
Figure 12.1 - Location of Gas Control Options
The unit must be reviewed to determine if any of the listed gas
control options were supplied.
POWER EXHAUSTER
RELAY
➀ Time Delay Relay
The Time Delay Relay is factory installed in the duct furnace
electrical junction box. The standard duct furnace is provided
for instantaneous fan operation. On a call for heat, the blower is
energized at the same time as the gas controls. The optional time
delay relay allows the gas controls to operate for approximately 30
seconds before the blower starts. This allows the heat exchanger
a warm up period so that the initial delivered air coming out of the
ductwork is not cool. The time delay relay also keeps the motor
running for approximately 30 seconds after the call for heat has
been satisfied to remove the residual heat from the heat exchanger.
POWER
EXHAUSTER
MOTOR
(HFP ONLY)
ignition
controller
optional
control relay
➀
supply
power
terminal
strip
control
transformer
optional
discharge
air t-stat
➁
➂
➆
➄
➃
low voltage
terminal strip
➅
➁ Low Gas Pressure Switch
The low gas pressure switch is factory installed in the duct furnace
above the gas train. The switch monitors the gas pressure
upstream of all the gas controls and shuts off the electric supply
to the ignition controller and combination gas valve if low gas
pressure is experienced. This will shut off all gas flow to the burner.
The switch has an automatic reset so that if the gas pressure
is interrupted and then is returned, the switch will automatically
allow the unit to operate when gas conditions are returned to the
allowable range of the pressure switch. The pressure switch range
is 2" to 14" W.C. and should be set to insure that the minimum inlet
gas pressure is available (6" W.C. for natural gas, 11" W.C. for
propane gas).
➂ High Gas Pressure Switch
The high gas pressure switch is factory installed in the duct
furnace above the gas train. The switch monitors the gas pressure
downstream of all the gas controls and shuts off the electric supply
to the ignition controller and combination gas valve if high gas
pressure is experienced right before the manifold. This will shut off
all gas flow to the burner. The switch has a manual reset so that if
the gas pressure is too high, a service person must check the unit
to make sure that none of the gas controls have been damaged
by the high gas pressure and then reset the switch to allow the
unit to operate when gas conditions are returned to the allowable
range of the pressure switch. The pressure switch range is 2" to 16"
W.C. and should be set to insure that the maximum manifold gas
pressure is not exceeded (3.5" W.C. for natural gas, 10" W.C. for
propane gas).
➃ Supply Air Fire Stat
The fire stat is factory installed in the duct furnace electrical junction
box with the sensor in the discharge air stream. In case of elevated
temperatures in the supply air, the manual reset switch shuts
down the entire unit. If the limit temperature is exceeded, a service
person must inspect the unit for the cause of the high discharge
temperature, take corrective action, and then reset the switch.
➄ Timed Freeze Protection
The timed freeze protection system is factory installed in the duct
furnace electrical junction box with the sensor (30°-75°F adjustable)
factory installed in discharge air stream. On initial start-up, the
timed delay in the system allows the unit to go through the normal
ignition sequence. The timed delay is an automatic reset switch and
adjustable for 1-10 minutes. In the event that the unit fails to fire
after this period, the discharge air sensor will sense the cold air and
will shut down the entire unit.
12
➅ Air Flow Proving Switch
The air flow proving switch is factory installed in the duct furnace
electrical junction box. The air flow proving switch monitors the
pressure differential between the duct furnace and the atmosphere.
The purpose of the air flow proving switch is to cut power to the
gas controls if a positive pressure is not measured by the switch.
This could be caused by a lack of air movement through the heat
exchanger.
NOTE: The air flow proving switch will prevent any heat
exchanger warm-up (the unit should not be equipped with
a time delay relay) because the gas controls can not be
energized until air flow is proven.
Setting the Air Flow Proving Switch
The range of the air flow proving switch is adjustable between 0.17"
to 5.0" W.C.
1. Set the thermostat so that there is a call for heat. This should
start the blower and then the burner ignition sequence.
2. Turn the set screw of the pressure switch clockwise until it
stops. This will set the pressure at 5.0" W.C.
3. Turn the screw counter-clockwise until the gas controls light
and then one additional full turn (This is approximately 0.25''
W.C.). This will allow for dirty filters or any other slight static
pressure increases in the system.
➆ Manual Reset High Limit
The manual reset high limit switch is factory installed in place
of the standard automatic reset high limit switch located in the
duct furnace electrical junction box. In case of a failure of the
blower motor, blockage of the inlet air, etc., the manual reset
switch prevents the unit from cycling on the high limit. If the limit
temperature is exceeded, a service person must inspect the unit for
the cause of the high discharge temperature, take corrective action,
and then reset the switch.
5-571.4
dimensional data
Figure 13.1 - HFG Unit Drawing
33.50
b
A
a
e
8.40
f
DRILL LOCATOR
DIMPLES FOR GAS
PIPE ENTRY LOCATION
(FIELD DRILLED HOLE)
24.90
4.70
22.47
13.00
10.26
electrical c
connections
(both sides)
6.28
9.00
G
37.44
4.29
d
3.00
side view
bottom DRILL LOCATOR DIMPLES
FOR GAS PIPE ENTRY LOCATION
(FIELD DRILLED HOLE)
rear view
Figure 13.2 - Rail or Slab Type Mounting Base
B
2.35
Lifting hole
0.75 dia.
2.00 1.00
G
5.42
1.75
37.44
23.10
spreader
bar
gas
control
access
side
1.50
Lifting
hole
1.00 dia.
1.80
spreader
bar
1.75
3.00
Table 13.1 - Model HFG Dimensions (All dimensions in inches)
Model Size
A
B
C
E
F
G
Gas Connection Pipe Size
Unit Shipping
Approx.
Unit Net
Weight
Cap Net
75
100/125
150/175
200/225
250/300
350/400
19.22
31.96
18.98
14.20
36.11
25.50
1/2"
282#
207#
16#
19.22
34.46
18.98
14.20
36.11
28.00
1/2"
305#
225#
16#
19.22
38.72
18.98
14.20
36.11
32.25
1/2"
333#
248#
16#
19.22
40.84
22.98
14.20
40.11
34.38
1/2"
383#
288#
16#
21.31
43.86
22.98
15.18
40.11
37.40
3/4"
428#
318#
26#
24.64
55.38
22.98
18.38
40.11
48.92
3/4"
525#
400#
35#
5-571.4
13
dimensional data
Figure 14.1 - HFP Unit Drawing
B
33.50
POWER EXHAUSTER
DISCHARGE COVER
Q
9.50
R
8.40
4.16
F
DRILL LOCATOR
DIMPLES FOR GAS
PIPE ENTRY LOCATION
(FIELD DRILLED HOLE)
2.67
COMBUSTION AIR
INLET LOUVERS
24.90
4.70
22.47
3.00
1.72
13.00
D
ELECTRICAL
C
CONNECTIONS
(both sides)
6.28
10.26
9.00
3.00
G
BOTTOM DRILL LOCATOR
DIMPLES FOR GAS
PIPE ENTRY LOCATION
(FIELD DRILLED HOLE)
REAR VIEW
37.44
4.29
SIDE VIEW
Figure 14.2 - Rail or Slab Type Mounting Base
B
G
2.35
2.00 1.00
Lifting hole
0.75 dia.
5.42
1.75
37.44
23.10
spreader
bar
1.50
Lifting
hole
1.00 dia.
1.80
spreader
bar
1.75
3.00
Table 14.1 - Model HFP Dimensions (All dimensions in inches)
Model Size
B
C
D
F
G
Q
R
Gas Connection Pipe Size
Approx.Unit Shipping
WeightUnit Net
14
75
100/125
150/175
200/225
250/300
350/400
31.96
18.98
15.18
36.11
25.50
10.95
7
1/2"
292#
217#
34.46
18.98
17.69
36.11
28.00
10.95
7
1/2"
315#
235#
38.72
18.98
21.94
36.11
32.25
10.95
7
1/2"
343#
258#
40.84
22.98
24.06
40.11
34.38
11.58
9.9
1/2"
398#
303#
43.86
22.98
27.09
40.11
37.40
11.58
9.9
3/4"
443#
333#
55.38
22.98
38.60
40.11
48.92
11.58
9.9
3/4"
540#
415#
5-571.4
performance
Table 15.1 — Air Temperature Rise - Low Temperature Rise Duct Furnaces ➀ ➁ ➂
Air Temperature Rise Through Unit (°F)
Model Btu/Hr
20
25
30
35
40
45
50
55
60
Size
InputOutputMax Min
CFM
100
75
150
175
200
300
350
125
225
250
400
75,000
100,000
125,000
150,000
175,000
200,000
225,000
250,000
300,000
350,000
400,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
200,000
240,000
280,000
320,000
2778
3704
4630
5556
6481
7407
8333
9259
11111
12963
14815
2222
2963
3704
4444
5185
5926
6667
7407
8889
10370
11852
1852
2469
3086
3704
4321
4938
5556
6173
7407
8642
9877
1587
2116
2646
3175
3704
4233
4762
5291
6349
7407
8466
1389
1852
2315
2778
3241
3704
4167
4630
5556
6481
7407
1235
1646
2058
2469
2881
3292
3704
4115
4938
5761
6584
1111
1481
1852
2222
2593
2963
3333
3704
4444
5185
5926
1010
1347
1684
2020
2357
2694
3030
3367
4040
4714
5387
926
1235
1543
1852
2160
2469
2778
3086
3704
4321
4938
Table 15.2 — Air Temperature Rise - High Temperature Rise Duct Furnaces ➀ ➁ ➂
Air Temperature Rise Through Unit (°F)
Model Btu/Hr
20 ➃
40 ➃
50 ➃
60
65
70
75
80
85
90
95
100 ➄
Size
InputOutputMax Min
CFM
75
75,000 60,000 2778
1389
1111
926
855
794
741
694
654
617
585
556
100
100,000 80,000 3704
1852
1481
1235
1140
1058
988
926
871
823
780
741
125
125,000 100,000 4630
2315
1852
1543
1425
1323
1235
1157
1089
1029
975
926
150
150,000 120,000 5556
2778
2222
1852
1709
1587
1481
1389
1307
1235
1170
1111
175
175,000 140,000 6481
3241
2593
2160
1994
1852
1728
1620
1525
1440
1365
1296
200
200,000 160,000 7407
3704
2963
2469
2279
2116
1975
1852
1743
1646
1559
1481
225
225,000 180,000
8333
4167
3333
2778
2564
2381
2222
2083
1961
1852
1754
1667
250
250,000 200,000
9259
4630
3704
3086
2849
2646
2469
2315
2179
2058
1949
1852
300
300,000 240,000 11111
5556
4444
3704
3419
3175
2963
2778
2614
2469
2339
2222
350
350,000 280,000 11111➅
6481
5185
4321
3989
3704
3457
3241
3050
2881
2729
2593
400
400,000 320,000 11111➅
7407
5926
4938
4558
4233
3951
3704
3486
3292
3119
2963
➀
Ratings are shown for elevations up to 2000 feet. For higher elevations, the input rating should be reduced at the rate of 4% per 1000 feet elevation above sea level. For Canada, in
elevations between 2000 and 4500 feet, the unit must be derated to 90% of the rating listed above.
➁
➂
Units approved for use in California by CEC.
➃
➄
➅
High air temperature rise units include an air distribution baffle and restrictor change when compared to the low air temperature rise units. Field conversion of a high air
temperature rise to a low air temperature rise unit (or the opposite) requires a factory supplied conversion kit.
The certified range of the High Temperature Rise Duct Furnaces is 20°-100°F but it is recommended that they be used from 60°-100°F to reduce the system pressure drop.
For Variable Air Movement Applications, see page 11.
The maximum CFM for the 350 and 400 results in a 23°F and a 27°F air temperature rise (respectively) based on the maximum unit pressure drop.
Air Temperature and External Static Pressure Limits
The maximum allowable discharge air temperature is 150°F. The maximum allowable air temperature rise for Low Air Temperature
Rise Units is 60°F. The maximum allowable air temperature rise for High Air Temperature Rise Units is 100°F. All duct furnaces are
designed for a maximum allowable static pressure of 3.0" W.C. on the heat exchanger.
Figure 15.1
Recommended Unit Configurations
SINGLE TOP VIEW
2279 CFM
60OF ENTERING
AIR TEMP.
TANDEM TOP VIEW
2279 CFM
20OF ENTERING
AIR TEMP.
160,000
BTU/HR
OUTPUT
65OF
TEMP. RISE
160,000
BTU/HR
OUTPUT
65OF
TEMP. RISE
160,000
BTU/HR
OUTPUT
65OF
TEMP. RISE
PREHEAT
UNIT
REHEAT
UNIT
PARALLEL TOP VIEW
125OF DISCHARGE
AIR TEMP.
5698 CFM
20OF ENTERING
AIR TEMP.
150OF DISCHARGE
AIR TEMP.
5-571.4
200,000
BTU/HR
OUTPUT 65OF
TEMP. RISE
SEE SERVICE
CLEARANCES
85OF DISCHARGE
AIR TEMP.
200,000
BTU/HR
OUTPUT 65OF
TEMP. RISE
15
pressure drop curves
Figure 16.1
Low Air Temperature Rise Duct Furnace Pressure Drop vs. CFM Curves
1.4
250/300
1.2
Caution:
Do not exceed the CFM ranges
indicated in Table 15.1
1
Pressure DroP
(P " W.C.)
350/400
0.8
200/225
150/175
0.6
0.4
100/125
75
0.2
0
0
1000
2000
3000
4000
5000
6000
7000
8000
cfm
16
5-571.4
9000 10000 11000 12000 13000 14000 15000
pressure drop curves
Figure 17.1
High Air Temperature Rise Duct Furnace Pressure Drop vs. CFM Curves
3.0
HFP250/300
350/400
2.8
2.6
Caution:
Do not exceed the CFM ranges
indicated in Table 15.2
2.4
OFP200/225
HFP200/225
2.2
HFG150/175
150/175
2.0
HFG250/300
HFG250/300
Pressure DroP
(∆P " W.C.)
1.8
1.6
100/125
HFG100/125
1.4
1.2
1.0
HFG200/225
HFG200/225
HFG
7575
0.8
0.6
0.4
0.2
0.0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
cfm
5-571.4
17
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.
Blower Assembly
The blower assembly includes the bearings, drive sheaves and
belts.
Blower bearings should be checked and lubricated based on the
blower manufacturer’s recommendations. Bearings should also
be checked for any unusual wear and replaced if needed.
Drive sheaves should be checked at the same time the bearings
are inspected. Check to make sure the sheaves are in alignment
and are securely fastened to the blower and motor shafts.
Belt tension should be rechecked shortly after the unit has been
installed to check for belt stretching. After the initial start-up,
monthly checks are recommended.
Filters
Manifold Assembly Removal
To remove the manifold
1.
2.
3.
4.
Shut off gas and electric supply.
Remove the burner side access panel.
Disconnect gas manifold at ground union joint.
Remove the two screws holding the manifold to the heat
exchanger support.
5. Slide the manifold through the manifold bracket.
6. Clean the orifices and adjust the air shutters as necessary.
7. Follow steps 3-6 in reverse order to install the manifold
assembly.
8. Turn on the electric and gas supply.
9. Check the ground union joint for leaks with a soap solution.
Tighten if necessary.
10. Install the burner side access panel.
Figure 18.1
Manifold Assembly Removal
If the unit is supplied with a dirty filter switch and light, clean or
replace the filters any time the dirty filter light comes on.
Units which do not have a dirty filter warning light should have
the filters checked monthly. Clean or replace if necessary. In
dirty atmospheres, filter maintenance may be required more
often.
serial
plate
Duct Furnace
electrical
junction
box
When providing annual maintenance for the duct furnace, keep
the unit free from dust, dirt, grease and foreign matter. Pay
particular attention to:
1. The combustion air intake and exhaust vent cap louvered
openings.
2. The burner ports and pilot burner orifices (avoid the use of
hard, sharp instruments capable of damaging surfaces for
cleaning these ports). To check the burner port and pilot
burner orifice, see Burner and Pilot Assembly Removal.
3. The air shutters and main burner orifices (avoid the use of
hard, sharp instruments capable of damaging surfaces for
cleaning these orifices). To check the air shutters and main
burner orifices, see for Manifold Assembly Removal.
The heat exchanger should be checked annually for cracks
and discoloration of the tubes. If a crack is detected, the heat
exchanger should be replaced before the unit is put back into
service. If the tubes are dark gray, airflow across the heat
exchanger should be checked to insure that a blockage has not
occurred or the blower is operating properly.
Electrical Wiring
The electrical wiring should be checked annually for loose
connections or deteriorated insulation.
Gas Piping & Controls
The gas valves and piping should be checked annually for
general cleanliness and tightness.
The gas controls should be checked to insure that the unit is
operating properly.
18
ground
union
joint
manifold
burner side
access panel
heat exchanger
support
Burner and Pilot Assembly Removal
To remove the burner
1.
2.
3.
4.
Shut off gas and electric supply.
Remove the burner side access panel.
Disconnect the pilot supply line from the gas valve.
Disconnect the ignition cable from the ignition controller
(located in the electrical junction box). Feed the cable
through the bushing in the bottom of the electrical junction
box.
5. Remove the screws holding the burner side access panel.
Attached to the panel are the burner retaining pins that
align the burner.
5-571.4
maintenance
Burner and Pilot Assembly Removal
(continued)
6. Slide the burner assembly out. The pilot is attached to the
burner assembly.
7. Examine the burner and pilot assembly for cleanliness
and/or obstructions as necessary (see Duct Furnace for
cleaning instructions).
8. Replace the burner assembly in reverse order. In replacing
the burner, be certain that the rear burner slots are located
properly on the burner retaining pins. Do not force the
burner side access panel, it will not fit if the burner is not
properly aligned.
9. Reconnect the ignition cable and pilot gas supply line.
10. Install the burner side access panel.
11. Turn on the electric and gas supply.
Figure 19.1
Burner and Pilot Assembly Removal
heat
exchanger
support
air shutters
(not shown)
are located
on the
manifold
pilot
assembly
ignition
cable
pilot
supply
line
5-571.4
19
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.
Do not reuse any mechanical or electrical component which
has been wet. Such component must be replaced.
important
To check most of the Possible Remedies in the troubleshooting
guide listed in Table 20.1, refer to the applicable sections of the
manual.
Table 20.1
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.
7.
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.
1.
2.
3.
4.
5.
Defective valve.
Loose wiring.
Defective pilot sensor
Defective ignition controller.
Improper thermostat wiring.
Main burners do not light (Pilot is lit)
Lifting Flames (See Figure 21.1)
Yellow Tipping
(With propane gas, some yellow tipping
is always present.)
Flashback
Floating Flames (See Figure 21.2)
1.
2.
3.
4.
Open manual gas valve.
Turn on main power.
Purge gas line.
Check for plugged pilot orifice and clean
with compressed air if necessary.
5. Adjust to a maximum of 14" W.C.
Minimum for Natural Gas - 6" W.C.
Minimum for Propane Gas - 11" W.C.
6. Check wiring for 24 volts to valve.
a. Replace ignition controller.
b. Replace gas valve.
7.
a. Check all ignition controller wiring.
b. Replace sensor if cracked or worn
c. Replace ignition controller.
8. Check all safety devices (High limit, air
flow proving switch, power exhauster
centrifugal switch - HFP Models Only,
gas pressure switches, etc.) Determine
and correct problem. Reset if necessary.
1.
2.
3.
4.
5.
Replace valve.
Check wiring to gas valve.
Replace pilot sensor.
Replace ignition controller.
Verify wiring compared to wiring diagram.
1. Too much primary air.
1. Reduce primary air.
2. Main pressure set too high.
2. Adjust to a maximum of 14" W.C.
3. Orifice too large.
3. Check orifice size with those listed on the
serial plate.
1. Insufficient primary air.
2. Dirty orifice.
1. Increase primary air.
2. Check orifices and clean with
compressed air if necessary.
3. Check manifold, replace if necessary.
3. Misaligned orifice.
1. Too much primary air.
2. Main pressure set too high.
3. Orifice too large.
1. Reduce primary air.
2. Adjust to a maximum of 14" W.C.
3. Check orifice size with those listed on the
serial plate.
1. Insufficient primary air.
2. Main pressure set too high.
3. Orifice too large.
1. Increase primary air.
2. Adjust to a maximum of 14" W.C.
3. Check orifice size with those listed on the
serial plate.
4. Clean louvers in vent cap.
4. Blocked vent cap.
20
Possible Remedy
5-571.4
service & troubleshooting
Trouble
Flame Rollout (See Figure 21.3)
Not Enough Heat
Possible Cause
1. Main pressure set too high.
2. Orifice too large.
3. Blocked vent cap.
1.
2.
3.
1.
Unit cycling on high limit. ➀
a. Obstructions/leaks in duct system.
b. Main pressure set too high.
c. Blower motor not energized.
1.
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.
2.
3.
4. Thermostat malfunction.
5. Gas controls wired incorrectly.
6. Unit undersized.
Too Much Heat
1. Thermostat malfunction.
2. Gas controls do not shut-off.
a. Gas controls wired incorrectly.
b. Short circuit.
3. Main gas pressure set too high.
4. Defective gas valve.
Power Exhauster Motor will not start
(HFP Models Only)
Possible Remedy
1. Power supply is off.
2. No 24V power to thermostat. 3. Thermostat malfunction.
4. Defective power exhauster relay.
5. Defective power exhauster motor.
➀ Automatic Reset High Limit
The duct furnace comes standard with an automatic reset high
limit switch that will shut-off the gas should the discharge air
temperature become excessive. See Figure 12.1, indicator ➆ for
the location of either the standard automatic or optional manual
reset high limit switch. The switch should operate only when
something is seriously wrong with the unit operation. Anytime
the switch operates, correct the difficulty immediately or serious
damage may result. If the switch cuts off the gas supply during
normal operation, refer to the “Not Enough Heat” section of
Service & Troubleshooting.
Adjust to a maximum of 14" W.C.
Check orifice size with those listed on
the serial plate.
Clean louvers in vent cap.
a. Clean/correct duct system.
b. Adjust to a maximum of 14" W.C.
c. Check/correct to insure blower motor
operates within 45 seconds of when
‑ gas controls are energized.
d. Adjust belt tension.
e. Check/correct blower drive settings for
proper rpm.
f. Check/correct venting system.
g. Replace air distribution baffle.
h. Replace high limit switch.
Adjust main gas pressure.
Minimum for Natural Gas — 6" W.C.
Minimum for Propane Gas — 11" W.C.
Adjust outside air damper to decrease
outside air percentage (if possible).
4. Check/replace thermostat.
5. Check unit wiring against the wiring
diagram.
6. Check design conditions. If unit is
undersized, an additional unit(s) or other
heat source must be added.
1. Check/replace thermostat.
2.
a. Check unit wiring against the wiring
diagram.
b. Check for loose or worn wires.
3. Adjust to a maximum of 14" W.C.
4. Replace gas valve.
1.
2. 3.
4.
5.
Turn on main power.
Check control transformer.
Check/replace thermostat.
Replace power exhauster relay.
Replace power exhauster motor.
Figure 21.1
Lifting Flame Condition
Figure 21.2
Floating Flame Condition
5-571.4
Figure 21.3
Flame Rollout Appearance
21
replacement parts ordering
Ordering
When servicing, repairing or replacing parts on these units, locate the serial plate of the unit and always give the complete Model
Number and Serial Number from the serial plate. The serial plate is located on the door of the electrical control box. The part numbers
for some common replacement parts are listed on the sample serial plate (See Figure 22.1). For a complete description of the model
number, see Model Identification.
Figure 22.1
outDoor gas-fireD Duct furnace/
for inDustrial/commercial use
cHauDiere a` gaZ a` conDuit Pour eXterieur/
Pour usage inDustriel/commercial
Modine Manufacturing Company
1500 DeKoven Ave., Racine, WI 53403
Phone: 800.828.4328
MADE IN U.S.A.
TYPE OF GAS
TYPE DE GAZ
HFG200AFRHN10A1
09170936100123
6
IN. W.C.
PO.C.D’E
natural
MANIFOLD PRESSURE
PRESSION A LA TUBULURE
D’ ALIMENTATION
3.5
IN. W.C.
PO.C.D’E
20-100
ORIFICE SIZE
DIM. DE L’INJECTEUR
MAXIMUM EXTERNAL
STATIC PRESSURE
PRESSION STATIQUE
EXTERIEUR MAXIMUM
F
O
(in canaDa)
2000 to 4500 ft.
610 et 1370 m.
0 to 2000 ft.
0 et 610 m.
OUTPUT BTU/HR
RENDEMENT
BTU/HEURE
160000
MIN. INLET PRESS. FOR PURPOSE
OF INPUT ADJUSTMENT
PRESSION D’ ALIMENTATION
EN GAZ MIN. ADMISE
TEMPERATURE RISE RANGE
ELEVATION DE TEMPERATURE
INPUT BTU/HR
DEBIT CALORIFIQUE
BTU/HEURE
aPProvals
200000
180000
160000
144000
23
26
MIN.
CFM
MAX.
CFM
1481
7407
MIN. VARIABLE
SPEED CFM
*
1111
DESIGN CONFORMS TO: UL STD 1995
CERTIFIED TO: CAN/CSA C22.2 NO. 236
APPROVED FOR USE IN CA BY THE CEC WHEN EQUIPPED WITH IPI
115
APPROVED FOR USE IN MASSACHUSETTS
1
AMPS
0.35
60
1.
2.
3.
4.
5.
FOR OUTDOOR INSTALLATIONS ONLY.
MINIMUM AMBIENT TEMPERATURE -40 OF.
FOR INSTALLATION DOWN STREAM OF REFRIGERATION SYSTEMS.
INSTALL ON THE POSITIVE PRESSURE SIDE OF AIR CIRCULATING BLOWER.
FOR UNITS WITH MANUAL RESET HIGH LIMIT SWITCH, RESET BUTTON IS LOCATED IN ELECTRICAL
JUNCTION BOX.
6. (IN USA) FOR INSTALLATIONS ABOVE 2000 FEET, DERATE 4 PERCENT FOR EACH 1000 FEET
OF ELEVATION ABOVE SEA LEVEL.
ligHting instructions
1. OPEN ALL GAS VALVES. TURN ON POWER.
2. SET THERMOSTAT TO DESIRED SETTING.
Top View/
Vue de dessus
sHut DoWn instructions
1. TURN OFF POWER & CLOSE ALL GAS VALVES.
REFER TO INSTALLATION AND SERVICE MANUAL FOR MORE INSTRUCTIONS
* for units WitH tWo stage, mecHanical moDulation, or electronic moDulating gas
controls, a factory DiscHarge air controller anD no room tHermostat incluDeD.
Access
Side/
C™t
dÕacc s
2
9900100
general
Air flow / Air courant
1
MEA 135-99-E
ACCEPTED BY CITY OF NEW YORk:
PHASE
M
A
S
ANS Z83.8 - 96
CGA 2.8 - M86
combustible materials anD service
clearances
materiauX combustibles et DÉgagements
D ‘ entretien
common rePlacement Parts
for parts ordering, contact the parts wholesaler or the manufacturer’s representative serving your area. When inquiring about parts, always provide model number, serial number,
description and part number. When ordering parts, provide part number listed.
for service, contact your local qualified installation and service contractor or appropriate
utility company.
5H73205-1 Comb. Gas Control
5H73696- Ignition Control
3H34347-3 Pilot Assy. kit
5H74976-1 limit Control
5H74977-1 Transfomer
5H74818-1 Wiring Diagram
3H35628-6 Burner kit
3H35616-6 Heat Exch. kit
IN. W.C.
PO.C.D’E
3
VOLTS
air tHrougHPut
Debit D’air
DESIGN COMPLIES WITH DUCT FURNACE STANDARD:
LE
SERIAL NUMBER
NUMERO DE SERIE
MIN. INPUT BTU/HR
DEBIT CALORIFIQUE
MIN. BTU/HEURE
P
MODEL NUMBER
NUMERO DE MODELE
gÉnÉral
Non-Access
side/ NonC™t dÕ
acc ss
1
2.
3.
4.
5.
instructions D’allumage
Minimum clearance to combustibles is 0.0” from
bottom of unit mounting rail or 3” from bottom of
sheet metal casing. / Le dégagement minimum du
combustible est 0.0” du bas de la barre qui support
^ le.
l’élément ou 3” du bas de l’enveloppe de to
1. DUVRIR TOUTES LES ROBINETS A GAZ. DONNER LE COURANT.
2. REGLER LE THERMOSTAT SUR LA POSITION DESIREE.
instructions De fer meture
1. COUPER LE COURANT ET FERMER TOUTES LES ROBINETS A GAZ.
REFERREZ AU MANUAL D’INSTALLATION ET
DE SERVICE POUR PLUS D’ INSTRUCTIONS
OFP - Minimum clearance to combustibles is 1.0”
from rooftop. / OFP Les dimensions minima de
positionnement par rapport aux matériaux combustibles est de 1.0 po depuis le dessus de l’appareil.
FRONT &
REAR (B)
HFG
75
100/125
150/175
200/225
250/300
350/400
0”
0”
3”
4”
5”
11”
^le
* Pour aPPareils avec DeuX PHases moDulation
mÉcHaniQue, ou aPPareils De contro
^
` la manufacture,
De gaZ ÉlectriQues moDulÉs, un air controleur DÉcHarge installÉ a
et tHermostat De cHambre nÕestPas inclus.
FRONT &
ACCESS
SIDE A
SIDE C
REAR (B)
SIDE
HFG/HFP
HFP
(A)
HFG HFP
3”
3”
3”
4”
5”
11”
0”
0”
0”
0”
0”
0”
0”
0”
0”
0”
0”
0”
3”
3”
3”
3”
3”
3”
18”
20”
25”
27”
30”
41”
DEGAGEMENT
DE SERVICE
RECOMMENDE
DEGAGEMENT DU
MATERIAL
COMBUSTIBLE
RECOMMENDED
SERVICE
CLEARANCE
CLEARANCE TO
COMBUSTIBLE
MATERIALS
MODEL
SIZE
SEULEMENT POUR L’INSTALLATION EXTERIEURE
LA TEMPERATURE MINIMUM DE L’AIR DEHORS EST -40 O
C.
POUR L’INSTALLATION QUE SUIVE LES SYSTEMS REFRIGERANTS.
^ TÉ DE LA PRESSION POSITIVE DU VENTILATEUR.
INSTALLER DU CO
POUR APPAREILS AVEC INTERRUPTEUR REMIS MANUEL HAUT-LIMITE, REMISE EST SITUÉE
^
DANS LA BOI TE JUNCTION ÉLECTRIQUE. POUR REMETTRE PRESSER LE BOUTON.
NONACCESS
SIDE (C)
Dimension
Du
moDele
avant &
arriere
(b)
Hfg
avant &
arriere
(b)
HfP
cote c
Hfg/HfP
6”
6”
6”
6”
6”
6”
75
100/125
150/175
200/225
250/300
350/400
0”
0”
3”
4”
5”
11”
3”
3”
3”
4”
5”
11”
0”
0”
0”
0”
0”
0”
COTE A
HFG
HFP
0”
0”
0”
0”
0”
0”
3”
3”
3”
3”
3”
3”
cote
D’acces
(a)
18”
20”
25”
27”
30”
41”
cote
nonacces (c)
6”
6”
6”
6”
6”
6”
5H74930B Rev F
22
5-571.4
model identification
Weatherproof Model Nomenclature
1
PT
2
UC
3
V
4 5 6
MBH
7
HE
8
DS
9
AS
10
ATR
11
GT
12
GV
13
SS
14
SV
15
TR
1 - Product Type (PT)
H - Outdoor HVAC Unit
2 -Unit Configuration (UC)
F - Furnace
3 - Venting (V)
G - Gravity
P - Power
4,5,6 - Furnace Input Rating (MBH)
225 - 225,000 Btu/Hr Input
75 - 75,000 Btu/Hr Input
250 - 250,000 Btu/Hr Input
100 - 100,000 Btu/Hr Input
300 - 300,000 Btu/Hr Input
125 - 125,000 Btu/Hr Input
350 - 350,000 Btu/Hr Input
150 - 150,000 Btu/Hr Input
400 - 400,000 Btu/Hr Input
175 - 175,000 Btu/Hr Input
200 - 200,000 Btu/Hr Input
7 - Heat Exchanger/Burner/Drip Pan Material (HE)
A - Aluminized Steel
S - 409 Stainless Steel Heat Exchanger/Burner
T - 409 Stainless Steel Heat Exchanger/Burner/Drip Pan
8 - Development Sequence (DS)
F - Single Stage
M - 2-stage or Modulating
9 - Access Side (AS)
R - Right Hand
L - Left hand
10 - Air Temperature Rise (ATR)
H - High 20°-100°F
L - Low 20°-60°
11 - Gas Type (GT)
N - Natural with continuous retry ignition controller
P - Propane with lockout ignition controller
12 - Gas Valve (GV)
1 - Single Stage
6 - Electronic Modulation Slave
2 - Two Stage
7 - Electronic Modulation 0-10 Vdc External Input
4 - Electronic Modulation
8 - Electronic Modulation 4-20 mA External Input
5 - Electronic Modulation Master
13 - Additional Safety Switches (SS)
0 - No Additional Switches
1 - Low Gas Pressure Switch
2 - High Gas Pressure Switch
3 - High & Low Gas Pressure Switch
14 - Supply Voltage (SV)
A - 115/60/1
E - 230/60/3
B - 208/60/1
F - 460/60/3
C - 230/60/1
G - 575/60/3
D - 208/60/3
15 - Transformer (TR)
1 - 40 VA
3 - 150 VA
2 - 75 VA
4 - 250 VA
0 - None
Figure 23.1 - Serial Number Designations
S
09
17
09
36
10
0123 10000
SERIAL NUMBER PREFIX
<blank> if standard
"S" if Special Product Order
SPO NUMBER
<blank> if standard
##### if Special Product Order
SERIES IDENTITY NUMBER
SEQUENTIAL NUMBER
Varies - 0000 TO 9999
Each unit in a week has a
unique number
CONTROL SUPPLIER
01-Robertshaw 09-White Rodgers
05-Honeywell 17-United Technologies
08-Fenwal
YEAR
PRODUCED
GAS VALVE SUPPLIER
01-Robertshaw 09-White Rodgers
05-Honeywell
WEEK
PRODUCED
5-571.4
23
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. This warranty covers replacement of any parts furnished from the
factory of Seller, but does not cover labor of any kind and materials not
furnished by Seller, or any charges for any such labor or materials, whether
such labor, materials or charges thereon are due to replacement of parts,
adjustments, repairs, or any other work done. This warranty does not apply to
any equipment which shall have been repaired or altered outside the factory of
Seller in any way so as, in the judgment of Seller, to affect its stability, nor
which has been subjected to misuse, negligence, or operating conditions in
excess of those for which such equipment was designed. This warranty does
not cover the effects of physical or chemical properties of water or steam or
other liquids or gases used in the equipment.
BUYER AGREES THAT SELLER’S WARRANTY OF ITS PRODUCTS TO
BE FREE FROM DEFECT IN MATERIAL AND WORKMANSHIP, AS LIMITED
HEREIN, SHALL BE IN LIEU OF AND EXCLUSIVE OF ALL OTHER
WARRANTIES, EITHER EXPRESS OR IMPLIED, WHETHER ARISING
FROM LAW, COURSE OF DEALING, USAGE OF TRADE, OR OTHERWISE,
THERE ARE NO OTHER WARRANTIES, INCLUDING WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PURPOSE, WHICH EXTEND
BEYOND THE PRODUCT DESCRIPTION CONFIRMED BY BUYER AND
SELLER AS OF THE DATE OF FINAL AGREEMENT.
This warranty is void if the input to the product exceeds the rated input as
indicated on the product serial plate by more than 5% on gas-fired and oil-fired
units, or if the product in the judgment of SELLER has been installed in a
corrosive atmosphere, or subjected to corrosive fluids or gases, been
subjected to misuse, negligence, accident, excessive thermal shock, excessive
humidity, physical damage, impact, abrasion, unauthorized alterations, or
operation contrary to SELLER’S printed instructions, or if the serial number has
been altered, defaced or removed.
BUYER’S REMEDY FOR BREACH OF WARRANTY, EXCLUSIVE OF ALL
OTHER REMEDIES PROVIDED BY LAW, IS LIMITED TO REPAIR OR
REPLACEMENT AT THE FACTORY OF SELLER, ANY COMPONENT WHICH
Component
Applicable Models
Heat Exchangers
Gas-Fired Units except PSH/BSH
Heat Exchangers
Low Intensity Infrared Units
Compressors
Condensing Units for Cassettes
Burners
Low Intensity Infrared Units
Other
Components excluding Heat Exchangers,
Coils, Condensers, Burners, Sheet Metal
SHALL, WITHIN THE APPLICABLE WARRANTY PERIOD DEFINED HEREIN
AND UPON PRIOR WRITTEN APPROVAL, BE RETURNED TO SELLER
WITH TRANSPORTATION CHARGES PREPAID AND WHICH THE
EXAMINATION OF SELLER SHALL DISCLOSE TO HAVE BEEN DEFECTIVE;
EXCEPT THAT WHEN THE PRODUCT IS TO BE USED BY BUYER AS A
COMPONENT PART OF EQUIPMENT MANUFACTURED BY BUYER,
BUYER’S REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE
LIMITED TO ONE YEAR FROM DATE OF SHIPMENT FROM SELLER. FOR
GAS-FIRED PRODUCTS INSTALLED IN HIGH HUMIDITY APPLICATIONS
AND UTILIZING STAINLESS STEEL HEAT EXCHANGERS, BUYER’S
REMEDY FOR BREACH, AS LIMITED HEREIN, SHALL BE LIMITED TO TEN
YEARS FROM DATE OF SHIPMENT FROM SELLER.
These warranties are issued only to the original owner-user and cannot be
transferred or assigned. No provision is made in these warranties for any
labor allowance or field labor participation. Seller will not honor any expenses
incurred in its behalf with regard to repairs to any of Seller’s products. No
credit shall be issued for any defective part returned without proper written
authorization (including, but not limited to, model number, serial number, date
of failure, etc.) and freight prepaid.
OPTIONAL SUPPLEMENTAL WARRANTY
Provided a supplemental warranty has been purchased, Seller extends the
warranty herein for an additional four (4) years on certain compressors.
Provided a supplemental warranty has been purchased, Seller extends the
warranty herein for an additional four (4) years or nine (9) years on certain
heat exchangers.
EXCLUSION OF CONSUMABLES & CONDITIONS BEYOND
SELLER’S CONTROL
The above referenced warranty shall not be applicable to any of the following
items: refrigerant gas, belts, filters, fuses and other items consumed or worn
out by normal wear and tear or conditions beyond Seller’s control, including
(without limitation as to generality) polluted or contaminated or foreign matter
contained in the air or water utilized for heat exchanger (condenser) cooling or
if the failure of the part is caused by improper air or water supply, or improper
or incorrect sizing of power supply.
“APPLICABLE WARRANTY PERIOD”
TEN YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
TEN YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN TEN YEARS
FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN ONE
HUNDRED TWENTY-SIX MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER
OCCURS FIRST
FIVE YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
FIVE YEARS FROM DATE OF RESALE BY BUYER OR ANY OTHER USER, WITHIN FIVE YEARS
FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN SIXTY-SIX
MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
TWO YEARS FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
TWO YEARS FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN
THIRTY MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
Heat Exchangers/Coils
Indoor and Outdoor Duct Furnaces and
System Units, PSH/BSH, Steam/Hot Water Units,
Oil-Fired Units, Electric Units, Cassettes,
Vertical Unit Ventilators
Compressors
Vertical Unit Ventilators
ONE YEAR FROM DATE OF FIRST BENEFICIAL USE BY BUYER OR ANY OTHER USER, WITHIN
ONE YEAR FROM DATE OF RESALE BY BUYER IN ANY UNCHANGED CONDITION, OR WITHIN
EIGHTEEN MONTHS FROM DATE OF SHIPMENT FROM SELLER, WHICHEVER OCCURS FIRST
Burners
High Intensity Infrared Units
Sheet Metal Parts
All Products
As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.
Commercial Products Group
Modine Manufacturing Company
1500 DeKoven Avenue
Racine, WI 53403
Phone: 1.800.828.4328 (HEAT)
www.modine.com
© Modine Manufacturing Company 2010
Litho in USA
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