Service manual

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THIS MANUAL IS THE PROPERTY OF THE OWNER.

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

Inspection on Arrival

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

immediately to transportation company and your local

Modine sales representative.

Check rating plate on unit to verify that power supply meets

available electric power at the point of installation.

3. Inspect unit upon arrival for conformance with description of

product ordered (including specifications where applicable).

Table of Contents

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

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

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

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

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

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

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

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

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

Gas Connections ................................ 11

Electrical ...................................... 12

Installation with Ductwork.......................... 13

Requirements/Adjustments and Data for Blower Units..13-17

Start-Up Procedure/Operation ........................ 18

Unit Components .................................. 19

Performance Data - General ......................... 20

Performance Data - Downturn Hoods .................. 21

Dimensions.....................................22-23

Service/Troubleshooting............................. 24

Model/Serial Number/Replacement Parts ............... 25

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

INSTALLATION AND SERVICE MANUAL

separated combustion gas-fired unit heaters

model PTS and BTS

6-561.2

5H080106A

August, 2011

All models approved for use in California by the CEC, in New

York city by the MEA division, and in Massachusetts. Unit heater

is certified for non-residential applications.

1. Improper installation, adjustment, alteration,

service, or maintenance can cause property

damage, injury, or death, and could cause

exposure to substances which have been

determined by various state agencies to

cause cancer, birth defects, or other

reproductive harm. Read the installation,

operating, and maintenance instructions

thoroughly before installing or servicing

this equipment.

2. Do not locate ANY gas-fired units in areas

where chlorinated, halogenated, or acidic

vapors are present in the atmosphere.

These substances can cause premature

heat exchanger failure due to corrosion,

which can cause property damage, serious

injury, or death.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS:

1. Open windows.

2. Do not try to light any appliance.

3. Do not touch any electrical switch; do

not use any phone in your building.

4. Extinguish any open flame.

5. Immediately call your gas supplier from

a neighbor’s phone. Follow the gas

supplier’s instructions. If you can not

reach your gas supplier, call your fire

department.

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open containers

in the vicinity of this appliance is hazardous.

The use of this manual is specifically intended

for a qualified installation and service agency.

All installation and service of these units

must be performed by a qualified installation

and service agency.

ARNING

IMPOR

ANT

Summary of content (28 pages)

PAGE 1
6-561.2 5H080106A August, 2011 installation and service manual separated combustion gas-fired unit heaters model PTS and BTS All models approved for use in California by the CEC, in New York city by the MEA division, and in Massachusetts. Unit heater is certified for non-residential applications. FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. WARNING 1.
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special precautions WARNING SPECIAL PRECAUTIONS THE INSTALLATION AND MAINTENANCE INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE, EFFICIENT AND TROUBLE-FREE OPERATION. IN ADDITION, PARTICULAR CARE MUST BE EXERCISED REGARDING THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. these instructions ARE Subject to any more restrictive local or national codes. 12.
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special precautions / SI (METRIC) CONVERSION FACTORS BEFORE YOU BEGIN CAUTION 16. Purging of air from gas supply line should be performed as described in the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest edition. In Canada, installation must be in accordance with CSA-B149.1. 17. When leak testing the gas supply piping system, the appliance and its combination gas control must be isolated during any pressure testing in excess of 14" W.C. (1/2 psi). 18.
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unit location UNIT LOCATION Figure 4.1 - Combustible Material and Service Clearances DANGER TOP Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere. CAUTION 1. Clearances to combustible materials are critical. Be sure to follow all listed requirements. 2. Heaters are designed for use in heating applications with ambient temperatures between -40°F and 90°F. 3. Do not install unit outdoors. 4.
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unit mOUNTING 1. Be sure the means of suspension is adequate to support the weight of the unit (see pages 22-23 for unit weights). 2. For proper operation, the unit must be installed in a level horizontal position. 3. Clearances to combustibles as specified in Table 4.1 must be strictly maintained. 4. All standard units are shipped fully boxed. Larger units are also supplied with skid supports on the bottom of the box.
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installation - venting A3. All heaters come with factory installed vent and combustion air adapters for attaching the vent pipe to the heater (4” for model sizes 150-200, 6” for model sizes 250-400). Attach the vent pipe to the adapter with 3 corrosion resistant screws. (Drill pilot holes through the vent pipe and adapter prior to screwing in place). Vent pipe must not be smaller than the connector size. A4.
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installation - venting A10. W hen the vent passes through a combustible INTERIOR wall or floor, a metal thimble 4" greater than the vent diameter is necessary. If there is 6' or more of vent pipe in the open space between the appliance and where the vent pipe passes through the wall or floor, the thimble need only be 2" greater than the diameter of the vent pipe. If a thimble is not used, all combustible material must be cut away to provide 6" of clearance.
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installation - venting Section B - Vertical 2-Pipe Vent System Installation Table 8.1 - Minimum Height from Roof to Lowest Discharge Opening B1. This section applies to vertically vented 2-pipe (one combustion air inlet pipe and one vent pipe) vent systems and is in addition to “Section A - General Instructions - All Units”. B2. Vertical vent systems terminate vertically (up). B3. It is recommended to install a tee with drip leg and clean out cap as shown in Figure 8.1. B4.
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installation - venting Figure 9.1 - Exhaust Vent Construction Through Combustible Walls and Support Bracket For Horizontally Vented Units (Refer to Figure 9.3): C oncentric adapter assembly (same for horizontal and vertical kits) FIBER GLASS INSULATION MIN. 2" METAL SLEEVE 2" MIN. S pecial vent termination cap (part #5H75150B1) Special inlet air guard VENT PIPE DIAMETER METAL FACE PLATE METAL SLEEVE 9" 2" MIN. 1" Figure 9.
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installation - venting For Horizontal Concentric Vent Kits For Vertical Concentric Vent Kits (refer to Figure 9.2): • Slide the combustion air cap down over the vent pipe and (refer to Figure 9.3): • The combustion air intake pipe must terminate at least 1 inch from the wall to prevent water from running down the wall and into the pipe. • The back of the vent cap must terminate at least 14 inches from the combustion air intake pipe. D7.
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installation - GAS CONNECTIONS GAS CONNECTIONS Figure 11.1 - Recommended Sediment Trap/Manual Shut-off Valve Installation - Side or Bottom Gas Connection WARNING GAS SUPPLY LINE 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.
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installation - ELECTRICAL connections ELECTRICAL CONNECTIONS 1. I nstallation 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. Two copies of the unit wiring diagram are provided with each unit.
PAGE 13
installation WITH DUCTWORK Figure 13.1- Typical Duct & Airflow Installation Recommended Installations A TURNING VANES 3" MIN. Dimension “B” Should Never Be Less than 1/2 of “A” B 3" MAX. C 12" MIN. 3" MIN. B B 12" MIN. 12" A 3" MAX. B 12" MIN. A A TURNING VANES BAFFLE SIDE VIEW TOP VIEW SIDE VIEW D 12" MIN. E F 12" MIN. B B A TURNING VANES BAFFLE A TURNING VANES BAFFLE SIDE VIEW SIDE VIEW IMPORTANT Do not attempt to attach ductwork of any kind to propeller models.
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installation To Install Blower Adjustments 1. Remove and discard the motor tie down strap and the shipping block beneath the motor adjustment screw (not used on all models.) 2. For 3 and 5 HP motors, affix sheave to the motor shaft and install motor on the motor mounting bracket. Install belt on blower and motor sheaves. Following electrical connections, check blower rotation to assure blow-through heating. If necessary interchange wiring to reverse blower rotation.
PAGE 15
BLOWER performance data - MODEL BTS Table 15.
PAGE 16
BLOWER PERFORMANCE DATA - MODEL BTS Table 16.1 - Blower Model BTS 150-250 (40-55°F temp rise for 250 size unit) External Static Pressure (“W.C.) 0.0 Model Size ATR CFM 40 2778 45 2469 50 2222 HP 1 1/2 1 2020 150 60 1852 573 510 1709 70 1587 40 3241 45 2881 55 2357 175 60 65 70 2161 1994 1852 3704 45 3292 2963 2469 4630 250 50 55 4115 3704 3367 229 3.0 - 232 5.0 232 3.5 230 2.5 230 0.5 1/2 - - 229 1 - - 1/4 230 1/3 0.4 0.5 0.6 0.
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BLOWER PERFORMANCE DATA - MODEL BTS Table 17.1 - Blower Model BTS 250-400 (60-70°F temp rise for 250 size unit) External Static Pressure ("W.C.) 0.0 Model Size ATR CFM HP 250 65 3086 2849 1 1-1/2 360 5556 45 4938 50 4444 3704 40 6481 45 5761 5185 4321 3.0 - - 530 241 2.0 23 5.0 566 241 1.5 23 4.0 601 241 0.5 23 3.0 635 - 241 0.0 1 23 2.0 1-1/2 - - - 180 4.5 180 2.5 2 - - - - - - - 1/2 - - - - 241 4.5 241 3.5 241 2.5 241 1.
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installation - operation OPERATION Prior to Operation IMPORTANT 1. To prevent premature heat exchanger failure, observe heat exchanger tubes. If the tubes become red while blower and furnace are in operation, check to be sure the blower has been set to the proper rpm for the application. Refer to page 14 for Blower Adjustments. 2. Start-up and adjustment procedures should be performed by a qualified service agency.
PAGE 19
CONTROL OPERATING SEQUENCE / unit components CONTROL OPERATING SEQUENCE Upon a call for heat from the thermostat, power is supplied to the power exhauster motor. The unit will go through a purge period and then the direct spark igniter will be energized. At the same time, the main valve in the combination control valve will open to allow gas to flow to the burners. If the fan motor has not already started it will start shortly.
PAGE 20
GENERAL PERFORMANCE DATA - MODELS PTS & BTS Table 20.1 - Propeller Unit Model PTS General Performance Data Model PTS Sizes 150 175 200 250 300 350 400 Btu/Hr Input 150,000 175,000 200,000 250,000 300,000 350,000 400,000 Btu/Hr Ouput 120,000 140,000 160,000 200,000 240,000 280,000 320,000 Entering Airflow (CFM) @ 70°F 2140 2725 3015 3995 4545 5280 5995 Outlet Velocity (FPM) 711 607 673 721 824 748 851 Air Temp. Rise (°F) 53 48 50 47 50 50 51 Max. Mounting Height (Ft.
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PERFORMANCE DATA - HOODS FOR PROPELLER MODELS Figure 21.1 - 30°, 60°, and 90° Downward Deflector Hoods Figure 21.3 - 90° Hood Throw/Floor Coverage H 30° HOOD 90° HOOD 60° HOOD S S Figure 21.2 - 30° and 60° Throw/Floor Coverage 30 DOWNTURN 60 DOWNTURN Table 21.
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DIMENSIONAL DATA - MODEL PTS Propeller Units - Model PTS Figure 22.1 - Dimensional Drawings R ADJUSTABLE LOUVERS A G 4 MOUNTING HOLES U T POWER VENTER VENT PIPE CONNECTION S COMBUSTION AIR INLET ACCESS PANEL B GAS CONNECTION E OPENING L J K D OPENING C H M (APPROX) Q (MIN DIST TO WALL) Table 22.1 - Dimensions (inches) - PTS Models PTS150 PTS175 PTS200 PTS250 PTS300 PTS350 PTS400 A 35.53 42.53 42.53 42.53 42.53 42.53 42.53 B 23.06 25.81 25.81 31.31 31.31 39.56 39.
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DIMENSIONAL DATA - MODEL BTS Blower Units - Model BTS Figure 23.1 - Dimensional Drawings 6 MOUNTING HOLES G ADJUSTABLE LOUVERS R A BLOWER ENCLOSURE (OPTIONAL) 4 7/8" T FILTER RACK (OPTIONAL) 7/8" U W X V S POWER VENTER VENT PIPE CONNECTION COMBUSTION AIR INLET ACCESS PANEL B OxP E OPENING L J C K D OPENING N MOTOR CORD STRAIN RELIEF M (APPROX.) I F GAS CONNECTION T-STAT CONNECTION ELECTRICAL CONNECTION H Q (MIN DIST TO WALL) Table 23.
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service / maintenance / troubleshooting WARNING When servicing or repairing of this equipment, use only factory-approved service replacement parts. A complete replacement parts list may be obtained by contacting the factory. Refer to the rating plate on the appliance for complete appliance model number, serial number, and company address. Any substitution of parts or controls not approved by the factory will be at the owner’s risk. CAUTION 1.
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serial & model number / replacement parts Model Number Designations (Remove access cover to locate) PTS 200 A S 01 11 Control Code Type (refer to page 12) 11 - Natural gas, single stage 12 - Natural gas, two-stage 21 - Propane, single stage 22 - Propane, two-stage Separated Combustion Unit Configuration PTS - Propeller Unit, 150-400MBH BTS - Blower Unit, 150-400MBH MBH Input (refer to pages 6 & 7) 150 - 150,000 Btu/hr input 200 - 200,000 Btu/hr input 250 - 250,000 Btu/hr input etc.
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commercial Warranty Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed.