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Modine Manufacturing DBP Installation And Service Manual

Manual is about: gas-fired indoor power vented duct furnace/make-up air units

Summary of DBP

  • Page 1

    Caution to prevent premature heat exchanger failure do not locate any gas-fired units in areas where chlorinated, halogenated, or acid vapors are present in the atmosphere. Warning improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death, and c...

  • Page 2: Warning

    5-565.1 2 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...

  • Page 3: Danger

    5-565.1 3 unit location location recommendations 1. When locating the furnace, consider general space and heating requirements, availability of gas and electrical supply, and proximity to vent locations. 2. Unit must be installed on the positive pressure side of the circulating blower. 3. Be sure th...

  • Page 4

    5-565.1 4 model blower type dbp units dcp units all units dbp units size (digit 16) (a) (a) (b) (c) 75 all 86.27 115.48 33.85 - 100/25 all 86.37 115.48 36.36 - 150/175 all 86.37 115.48 40.61 - 200/225 all 86.37 115.48 42.71 - 250/300 e,f,g, or h 86.37 115.48 45.75 - 250/300 i,j, or k 112.12 151.34 4...

  • Page 5

    5-565.1 5 duct installation duct installation furnace discharge duct connection 1. The furnace discharge is designed to accept straight ductwork. (see figure 5.1.) provide an airtight seal between the ductwork and the furnace. Seams with cracks in the ductwork should be caulked and/or taped and be o...

  • Page 6: Warning

    5-565.1 6 7. Avoid venting through unheated space. When venting does pass through an unheated space, insulate runs greater than 5 feet to minimize condensation. Inspect for leakage prior to insulating and use insulation that is noncombustible with a rating of not less than 350°f. Install a tee fitti...

  • Page 7

    5-565.1 7 additional requirements for horizontally vented category iii units 1. Seal the joints with a metallic tape or silastic suitable for temperatures up to 350°f. (3m tapes 433 or 363 are acceptable.) wrap tape two full turns around the vent pipe. 2. Refer to table 7.2 for total minimum and max...

  • Page 8: Warning

    5-565.1 8 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 se...

  • Page 9: Warning

    5-565.1 9 electrical connections 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 electri- cally grounded in conformance to this code. In canada, wiring must comply with csa...

  • Page 10

    5-565.1 10 the cooling section includes a full coverage, 3-way sloping 409 stainless steel drain pan to remove condensate from coil headers, thermal expansion valves, and refrigerant piping. Insulation is standard on outdoor units and optional on indoor units and double wall construction is optional...

  • Page 11

    5-565.1 11 unit installation table 11.1 - cooling coil performance limits 8. Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to atmosphere. Measure the vacuum in the piping using a micron gauge located as far from the pump as possible (the vacuum at the pump ...

  • Page 12: Important

    5-565.1 12 unit installation / start-up procedure operation general - all coils 1. Proper air distribution is vital to coil performance. Air flow anywhere on the coil face should not vary by more than 20%. 2. Air velocities should be maintained between 200 and 550 feet per minute. 3. For chilled flu...

  • Page 13

    5-565.1 13 19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minumum inlet pressure should be 6" w.C. On natural gas and 11" w.C. On propane gas. The maximum inlet pressure for either gas is 14" w.C. If inlet pressure exceeds 14" w.C., a gas pressure regulator mus...

  • Page 14

    5-565.1 14 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...

  • Page 15: Important

    5-565.1 15 blower adjustments if blower fan speed changes are required, adjust motor sheave as follows: 1. Refer to page 34 to determine correct blower speed according to job requirements, then proceed with steps 2 through 8. 2. Loosen motor base and take belt off of motor sheave. 3. Loosen set scre...

  • Page 16

    5-565.1 16 start-up procedure single-stage gas controls (intermittent pilot) utilizes a single-stage combination gas control, an ignition control, and a single-stage low voltage thermostat. 1. The thermostat calls for heat. 2. The power exhauster relay is energized starting the power exhauster motor...

  • Page 17

    5-565.1 17 start-up procedure 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 informat...

  • Page 18

    5-565.1 18 options all units include the standard (std) features. The unit must be reviewed to determine the optional (opt) features that may have been supplied with the unit. (1) discharge thermostat – (opt) the discharge thermostat is factory installed in the discharge air stream of the unit. For ...

  • Page 19

    5-565.1 19 options b) two-stage electronic type thermostat - includes a factory installed discharge air sensor. The thermostat body is field installed remotely and includes the discharge air set point adjuster that must be field set. Refer to literature 5-577 latest revision. Figure 19.1 - two-stage...

  • Page 20: Warning

    5-565.1 20 (6) ignition controller – (opt) the ignition controller is factory installed in the duct furnace electrical junction box with the spark ignitor and sensor located on the burner. For both natural and propane gas units, the ignition controller is 100% shut-off with continuous retry. On a ca...

  • Page 21

    5-565.1 21 (20) extended grease line zerk fittings – (opt) the extended grease line zerk fittings are factory installed on the exterior corner post between the electrical and blower sections. The zerk fittings allow pillow block bearings to be lubricated with a grease gun. Refer to lubrication recom...

  • Page 22

    5-565.1 22 modulating damper actuator: a modulating damper actuator is provided with air control options ga, gb, gc, gd, ge, gf, gg, gh, gj, gk, gm, and gn (digits 20 & 21). The modulating damper actuator provides incremental operation of the fresh air damper (the return air damper is controlled by ...

  • Page 23: Warning

    5-565.1 23 options outdoor enthalpy changeover set point the outdoor enthalpy changeover set point returns the outdoor air damper to the minimum position when the enthalpy rises above its set point. Enthalpy set point scale markings, located on the enthalpy controller, are a, b, c, and d. See figure...

  • Page 24

    5-565.1 24 (40) motor starter – (opt) the motor starter is factory installed in the electrical section. A motor starter is required for all three phase motors and single phase motors 2 hp and greater. The motor starter current set point dial is factory set to the motor full load amp draw listed on t...

  • Page 25

    5-565.1 25 (47) electronic modulating gas valve – (opt) an electronic modulating gas valve is provided factory installed in the duct furnace gas train when the unit is equipped with electronic modulating gas controls (digit 12 = 4, 5, 6, 7, or 8). The gas valve modulates the firing rate between 40% ...

  • Page 26

    5-565.1 26 general performance data table 26.1 - general performance data - models with blower model size (digits 4-6) 75 100 125 150 175 btu/hr input ➀ 75,000 10,0000 125,000 150,000 175,000 btu/hr output ➀ 60,000 80,000 100,000 120,000 140,000 blower style (digit 16 letter) a or b c or d c or d e ...

  • Page 27

    5-565.1 27 general performance data table 27.1 - air temperature rise input output 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 max cfm min ➁ 75,000 60,000 2778 2222 1852 1587 1389 1235 1111 1010 926 855 794 741 694 654 617 585 556 100,000 80,000 3704 2963 2469 2116 1852 1646 1481 1347 1235 1...

  • Page 28

    5-565.1 28 selection procedure in order to properly select an indirect-fired heating, ventilating, cooling or make-up air unit, it is necessary to have the following basic information. 1. Required air handling capacity (cfm). The air capacity of the unit is usually determined by the ventilation air ...

  • Page 29

    5-565.1 29 10. Determine the supply voltage: from item #9 listed above, the 460v/60hz/3ph results in the supply voltage = f. 11. Determine the transformer: for dbp/dcp models, a 75va transformer is required. Thus, the transformer = 2. 12. Determine the blower size and bearing type: using table 26.1,...

  • Page 30

    5-565.1 30 all units weatherproof unit only unit size digit 16 cfm 75 a,b,c,d 100/125 c,d,e,f 150/175 c,d,e,f 200/225 c,d,e,f,g,h e,f,g,h 250/300 500/600 i,j,k,l e,f,g,h 350/400 700/800 840/960 i,j,k,l 556 0.01 0.01 0.02 0.03 0.01 0.05 0.02 0.07 0.00 0.01 0.00 600 0.01 0.01 0.02 0.03 0.01 0.05 0.02 ...

  • Page 31

    5-565.1 31 blower performance data 556 0.09 679 0.15 871 0.22 1031 0.29 1170 0.37 1296 0.45 1411 0.63 1617 0.81 1800 1.01 1968 700 0.14 747 0.21 924 0.29 1074 0.37 1206 0.46 1327 0.55 1438 0.75 1638 0.95 1818 1.17 1982 800 0.18 801 0.26 966 0.35 1109 0.44 1237 0.54 1354 0.64 1462 0.84 1658 1.06 1832...

  • Page 32

    5-565.1 32 air digit temp. Unit size 16 rise total static pressure, ''w.C. . 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 cfm m bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm blower performance data 250/300 e,f start 300 250/300 g,h start 300 250/300 i, j, k end 250 350/400 ...

  • Page 33

    5-565.1 33 air total static pressure inches "w.C. Unit temp 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 size digit 16 rise cfm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm bhp rpm 500/600 g or h start 600 500/600 i, j, k start 600 end 500 500/600 l start 500 700/800 g or h start ...

  • Page 34

    5-565.1 34 table 34.1 - digit 16 = a or b (9-7 blower units) rpm range motor frame 656-1001 978-1265 1150-1561 1526-1858 1763-2147 size digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly 48 a 3h35125b1 c 3h35125b3 56 b 3h35125...

  • Page 35

    5-565.1 35 blower sheave assembly data table 35.1 - digit 16 = e or f (12-12 blower units) rpm range motor frame 468-715 644-874 863-1078 1029-1332 1150-1438 1327-1659 size digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly digit 19 sheave assembly di...

  • Page 36

    5-565.1 36 blower sheave assembly data table 36.1 - blower sheave assembly settings sheave assembly turns open 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 blower rpm 3h35125b1-2 1001 966 932 897 863 828 794 759 725 690 656 3h35125b3-5 1265 1236 1208 1179 1150 1121 1093 1064 1035 1006 978 3h35125b6-7 1561 1520 1...

  • Page 37

    5-565.1 37 blower sheave assembly data table 37.1 - blower sheave assembly numbers and size sheave assembly motor sheave blower sheave browning belt no. Pitch diameter bore pitch diameter bore 3h35125b1 2.9 0.5 5 0.75 a30 3h35125b2 2.9 0.625 5 0.75 a31 3h35125b3 4.4 0.5 6 0.75 a34 3h35125b4 4.4 0.62...

  • Page 38

    5-565.1 38 total unit amp draw the total unit amp draw is a combination of the motor, the control step down transformer, and the power exhauster amp draw. The control step down transformer includes damper actuators, ignition controllers, gas valves, control relays, amplifiers, and motor starters. Un...

  • Page 39

    5-565.1 39 motor data table 39.1 - motor data for digit 14 = c - 230v/60hz/1ph ➀ refer to page 42 for motor type abbreviations. ➁ motors manufacturers do not rate single-phase motors for efficiency. Digits motor motor frame amp. Service thermal weight efficiency 17&18 size (hp) type ➀ size draw fact...

  • Page 40

    5-565.1 40 motor data table 40.1 - motor data for digit 14 = e - 230v/60hz/3ph ① ① motors have no thermal overload. ② refer to page 42 for motor type abbreviations. Motor digits size motor frame amp. Service weight efficiency 17&18 (hp) type ➁ size draw factor (lbs) (%) a1 or l1 1/3 odp 56 1.6 1.35 ...

  • Page 41

    5-565.1 41 motor data table 41.1 - motor data for digit 14 = f - 460v/60hz/3ph ➀ ➀ motors have no thermal overload. ➁ refer to page 42 for motor type abbreviations. Motor digits size motor frame amp. Service weight efficiency 17&18 (hp) type ➁ size draw factor (lbs) (% ) a1 or l1 1/3 odp 56 0.8 1.35...

  • Page 42

    5-565.1 42 motor data table 42.1 - motor data for digit 14 = g - 575v/60hz/3ph ➀ digits motor motor frame amp. Service weight efficiency 17&18 size (hp) type ➁ size draw factor (lbs) (%) a5 or l5 1/3 tefc 56 0.6 1.15 16 n/a b1 or m1 1/2 odp 56 0.9 1.25 25 n/a b5 or m5 1/2 tefc 56 0.9 1.15 24 n/a c1 ...

  • Page 43

    5-565.1 43 bottom electrical connection knockouts, identical size as side connections (only on access side) qty 2 - 1.06 dia. & qty 2 - 0.88 dia. Electrical connection knockouts (access side only) 43.23 24.00 g 9.21 3.00 5.29 5.29 1.50 j over roof 30.07 1.98 2.00 2.00 2.00 10.26 (approx) 23.07 (heig...

  • Page 44

    5-565.1 44 dimensions bottom electrical connection knockouts, identical size as side connections (only on access side) qty 2 - 0.88 dia. Electrical connection knockouts (access side only) qty 2 - 1.06 dia. Electrical connection knockouts (access side only) 43.23 24.00 g 9.21 3.00 5.29 5.29 1.50 j ov...

  • Page 45

    5-565.1 45 dimensions - base 0.75" suspension hanging locations (typical 4 corners) 0.63 2.36 1.45 return air opening 4.35 24.00 inside m e inside m c to end of unit a j b d k l n lifting point suspension point suspension point lifting point g figure 45.1 - unit base dimensions model blower type siz...

  • Page 46

    5-565.1 46 l 1.5 1.5 h w v i airflow direction top view fl fh airflow direction s 1.8 1.8 2.25 2.25 supply water line connection turned 90° in direction of airflow return water line connection turned 90° in direction of airflow coil for right hand units (digit 9 = r) headers on opposite side for lef...

  • Page 47

    5-565.1 47 dimensions/weights figure 47.1 - remote panel dimensions c 3.38 2.13 3.53 b 3.53 a 5.57 2.56 1.50 notes: 1. Holes visable on right side are also on left side in the same location. 2. Holes on top are also on the back in the same location horizontally, 1" down vertically. Table 47.3 - remo...

  • Page 48: Important

    5-565.1 48 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. Bl...

  • Page 49

    5-565.1 49 maintenance burner and pilot assembly removal to remove the burner 1. Shut off gas and electric supply. 2. Disconnect the pilot supply line from the gas valve. 3. Disconnect the ignition cable from the ignition controller (located in the electrical junction box). Feed the cable through th...

  • Page 50

    5-565.1 50 service & troubleshooting trouble possible cause possible remedy table 50.1 - troubleshooting power exhauster motor will not start 1. Power supply is off. 2. No 24v power to thermostat. 3. Thermostat malfunction. 4. Defective power exhauster relay. 5. Defective power exhauster motor. 1. T...

  • Page 51

    5-565.1 51 service & troubleshooting trouble possible cause possible remedy not enough heat 1. Unit cycling on high limit. ➀ a. Obstructions/leaks in duct system. B. Main pressure set too high. C. Blower motor not energized. D. Loose belt e. Blower speed too low. F. Blocked/damaged venting system. G...

  • Page 52: Sample

    5-565.1 52 sample model designations model identification duct furnace/make-up air units contain an etl/etl canada certified indoor duct furnace. This duct furnace is combined with either a blower section or a blower and cooling section to make a complete make-up air or heating/ventilating/ cooling ...

  • Page 53

    5-565.1 53 figure 53.1 - model identification plate figure 53.2 - serial number designation figure 53.3 - serial number designations 101 01 02 - 1000 series identity number identifies which series of controls were furnished on the unit. Sequence number year of manufacture 01 – 2001 02 – 2002 etc. We...

  • Page 54

    5-565.1 54 job name: date: address: model no.: city & state: order no.: start-up check list “all items must be checked” serial no.: 1. All shipping straps, braces, tie downs removed? ____ yes ___ no 2. Unit installed level and secure? ____ yes ___ no 3. Gas burner properly located and aligned? ____ ...

  • Page 55

    5-565.1 55 model nomenclature for system units 1 - product type (pt) i - indoor hvac unit 2 - unit configuration (uc) f - furnace b - blower package - furnace & blower c - cooling package - furnace, blower & cooling 3 - venting (v) p - power 4,5,6 - furnace input rating (mbh) (output on 840 & 960) 7...

  • Page 56

    Commercial products group modine manufacturing company 1500 dekoven avenue racine, wi 53403 phone: 1.800.828.4328 (heat) www.Modine.Com litho in usa © modine manufacturing company 2009 commercial warranty seller warrants its products to be free from defects in material and workmanship, exclusive, ho...