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indirect gas-fired indoor separated combustion make-up air units
WARNING
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. Installing, starting up and servicing heating,
ventilation and air conditioning equipment
poses significant hazards and requires
specialized knowledge of Modine products
and training in performing those services.
Failure to have any service properly
performed by, or making any modification
to Modine equipment without the use of
qualified service personnel could result in
serious injury to person and property,
including death. Therefore, only qualified
service personnel should work on any
Modine products.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
INSTALLATION AND SERVICE MANUAL
THIS MANUAL IS THE PROPERTY OF THE OWNER.
All models approved for use in California by the CEC.
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.
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.
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).
5-594.10
5H0768560001
December, 2020
models DBS/DCS
IBS/ICS
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Table of Contents
Related Manuals for Modine Manufacturing DBS
Summary of Contents for Modine Manufacturing DBS
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Page 1: Inspection On Arrival
5-594.10 5H0768560001 December, 2020 INSTALLATION AND SERVICE MANUAL indirect gas-fired indoor separated combustion make-up air units models DBS/DCS IBS/ICS All models approved for use in California by the CEC. 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. -
Page 2: Special Precautions
DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. complete replacement parts list may be obtained by THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE contacting Modine Manufacturing Company. Refer RESTRICTIVE LOCAL OR NATIONAL CODES. to the rating plate on the appliance for complete... -
Page 3: Table Of Contents
Inspection on Arrival ....... . .1 Modine Manufacturing Company will sometimes build units Special Precautions . -
Page 4: Unit Location
UNIT LOCATION / UNIT MOUNTING METHODS Figure 4.1 - Combustible Material Clearances UNIT LOCATION Model Size Access Side (A) DANGER 75 thru 175 1" 200 thru 960 2" Appliances must not be installed where they may be exposed to a potentially explosive or flammable atmosphere. TOP = 3"... -
Page 5: Unit Lifting
UNIT MOUNTING METHODS / UNIT LIFTING Figure 5.1 - Unit Suspension Method UNIT LIFTING WARNING ELECTRICAL SUSPENSION SECTION RODS DOOR Failure to follow proper lifting instructions and applicable safety procedures could result in property damage, serious injury, or death. Lifting should only be done by a qualified rigging company. -
Page 6: Duct Connection To Unit
DUCT CONNECTIONS / UTILITY CONNECTIONS / UNIT INSTALLATION DUCT CONNECTION TO UNIT Figure 6.3 - Recommended Field Installed Discharge Duct Configurations for Blower Package Units 1. The furnace discharge (units with Model Digit 2=B) is designed to accept straight ductwork (see Figure 6.1.). DIMENSION “B”... - Page 7 INSTALLATION - VENTING A3. All heaters come with factory installed vent and combustion W ARNING air adapters for attaching the pipe to the heater. The pipe diameters are 4" for model sizes 75-175 and 6" for model sizes 200-400. All units are classified as Category III 1.
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Page 8: Venting
INSTALLATION - VENTING Figure 8.1 - Venting Through Combustible Roof or Wall A19. Long runs of horizontal or vertical combustion air pipes may require insulation in very cold climates to prevent the LISTED buildup of condensation on the outside of the pipe where LISTED the pipe passes through conditioned spaces. - Page 9 INSTALLATION - VENTING Section B - Vertical 2-Pipe Vent System Figure 9.2 - Vertical Venting - 2 Pipes Flat Roof Installation LISTED VENT B1. This section applies to vertically vented 2-pipe (one TERMINAL DISTANCE “D” TO combustion air inlet pipe and one vent pipe) vent systems WALL OR ADJOINING LISTED AIR BUILDNG...
- Page 10 INSTALLATION - VENTING Section C - Horizontal 2-Pipe Vent Installation Section D - Concentric Vent System Installation C1. This section applies to horizontally vented 2-pipe vent systems (one combustion air inlet pipe and one vent pipe) and CAUTION is in addition to “Section A - General Instructions - All Units”. C2.
- Page 11 INSTALLATION - VENTING D3. Once the kit contents have been verified as correct for the D9. Slide the combustion air pipe over the vent pipe and attach direction of venting, the concentric vent adapter box is to to the air inlet of the concentric adapter box, as shown in be installed.
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Page 12: Gas Connections
INSTALLATION - GAS CONNECTIONS Gas Connections The gas piping to the unit can enter the unit from the side of the unit or from below. Install a ground joint union with brass WARNING 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"... - Page 13 INSTALLATION - GAS CONNECTIONS Table 13.3 - Burner Orifice Sizing and Gas Consumption Table 13.1 - Gas Pipe Capacities - Natural Gas j Capacity in MBH by Nominal Pipe Diameter Gas Type Pipe Model Orifice Length (ft) 1∕2” 3∕4” 1” 1 1∕4”...
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Page 14: Considerations For Elevation
Equation 14.1 - Manifold Pressure for Gas Heating Values Different Than Shown in Table 14.1 The standard ratings for Models DBS/DCS are certified for elevations up to 2000 feet above sea level. Operation at elevations above 2,000 feet requires ratings be reduced 4% for each 1000 feet above sea level per ANSI Z223.1. -
Page 15: Electrical Connections
INSTALLATION - ELECTRICAL CONNECTIONS Electrical Connections The wire gauge must be sized according to the National Electric Code or CSA code based on the power supply WARNING voltage, amp draw, and length of run. Refer to the Table 15.1 for maximum wire lengths. Table 15.1 - 24V and Digital Control Wire Lengths 1. - Page 16 INSTALLATION - ELECTRICAL CONNECTIONS Depending on the configuration of the unit controls, Figure 16.1 - Recommended Field Installed there may be sensors that are field installed. Review the Disconnect Switch Mounting Location unit ordered to verify that the sensors supplied match the configuration of the unit.
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Page 18: Cooling Coil Specifications And Installation
INSTALLATION - COOLING COIL UNITS Cooling Coil Units Direct Expansion (DX) Piping Models with a cooling section can be provided with either a The refrigerant lines should be insulated to prevent warming factory installed direct expansion (DX) evaporator, a chilled or cooling of the refrigerant. - Page 19 INSTALLATION - COOLING COIL UNITS Figure 19.1 - General Chilled Fluid Piping 9. Failure to obtain a high vacuum is indicative of a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks (soapy water works well).
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Page 20: Start-Up Procedure
START-UP PROCEDURE Start-Up Procedure 19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minumum inlet pressure should IMPORTANT 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"... -
Page 21: Main Burner Adjustment
START-UP PROCEDURE Main Burner Adjustment After adjustment, move the field installed manual shut-off valve to the “OFF” position, remove the manometer, and The gas pressure regulator (integral to the combination gas replace the 1/8" pipe plug. control) is adjusted at the factory for average gas conditions. After the plug is in place, move the field installed manual It is important that gas be supplied to the duct furnace in shut-off valve to the “ON”... -
Page 22: Air Shutter Adjustment
START-UP PROCEDURE Check/Adjust Pressure for the Modulating Valve Save the setting by simultaneously holding Buttons (continued) #1 and #2 until the LED turns OFF. If this is not performed within 5 minutes, the control will default 11. After the plug is in place, move the field installed manual to the previously saved settings and return to normal shut-off valve to the “ON”... -
Page 23: Blower Adjustment
START-UP PROCEDURE Blower Adjustments Lubrication Recommendations If blower fan speed changes are required, adjust motor sheave The blower can be provided with either spider or pillow block as follows: bearings. Spider bearings are permanently lubricated and do not require lubrication. Pillow block bearings are shipped greased 1. -
Page 24: Furnace Control Operating Sequence
START- UP PROCEDURE Furnace Control Operating Sequence Once the pilot is lit, the flame sensor proves the pilot and stops the spark igniter from sparking. IMPORTANT The main gas valve is opened and the main burner is controlled as follows: To prevent premature heat exchanger failure, with all control Single-Stage Furnaces (Model Digit 12=1): The main systems, a blower starting mechanism must be provided so... -
Page 25: Variable Air Volume Applications
Multiple Furnace Controls Extended VAV Airflow Limits If certain conditions are followed, the allowable minimum CFM Multiple furnace units are available as two furnace units (Model of the system can be extended to: Digits 4-6=500 through 800) and three furnace units (Model Digits 4-6=840 or 960) and with different types of gas control: •... - Page 26 COMPONENT LOCATIONS Figure 26.1 - Factory Mounted Option Locations Discharge Thermostat (not shown) Low Gas Pressure Switch High Gas Pressure Switch Power Exhauster Assembly Timed Freeze Protection Ignition Controller Differential Pressure Switch Control Relay Time Delay Relay 10. Furnace Low Voltage Terminal Strip 11.
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Page 27: Component Descriptions
COMPONENT DESCRIPTIONS All units include the standard (STD) features. The unit (2) Low Gas Pressure Switch – (OPT) must be reviewed to determine the optional (OPT) The switch monitors the gas pressure upstream of all the gas features that may have been supplied with the unit. controls and disables the ignition controller and combination gas valve if low gas pressure is experienced. - Page 28 COMPONENT DESCRIPTIONS 6) Ignition Controller – (STD) (12) Furnace Supply Power Terminal Strip – (STD) The ignition controller is factory installed in the duct furnace The furnace supply power terminal strip is located in the duct electrical junction box with the spark ignitor and sensor located furnace electrical junction box.
- Page 29 COMPONENT DESCRIPTIONS Figure 29.1 - Dead Front Disconnect Switch Assembly (20, 21) Extended Grease Lines – (OPT) The extended grease lines (21) are factory installed in the BLOWER SECTION blower section and include Zerk® grease fittings (20) factory ELECTRICAL installed on the exterior corner post between the electrical and COMPARTMENT ACCESS DOOR blower sections.
- Page 30 COMPONENT DESCRIPTIONS Figure 30.1 - Two-Position Damper Actuator Limiter (27) Fresh Air Damper – (OPT) When a fresh air damper is supplied with the unit, the damper is factory installed in the blower section. The fresh air damper is used as an outside air shut-off damper, so ultra low leak, Class I leakage resistance (less than 4 CFM/ft²...
- Page 31 COMPONENT DESCRIPTIONS the space pressure controller energizes the actuator to (32) Damper to Damper Linkage – (OPT) drive the fresh air damper closed. When below the desired Units with fresh and return air dampers include a damper low pressure setpoint, a contact on the space pressure actuator that controls the fresh air damper.
- Page 32 COMPONENT DESCRIPTIONS (37) Convenience Outlet – (OPT) (39) Dirty Filter Switch – (OPT) The dirty filter pressure switch is factory installed in the blower WARNING electrical section. The switch monitors the pressure differential between the two sides of the filters. When the filters become Do not perform service on the convenience outlet without dirty, the differential pressure increases and trips the pressure disconnecting its power supply.
- Page 33 COMPONENT DESCRIPTIONS (40) Motor Starter – (OPT) (41) Mild Temperature Stat - (OPT) (All Except Digit 12=9) The mild temperature thermostat is designed to lockout the The motor starter is factory installed in the blower electrical burner during mild weather conditions which prevents the section.
- Page 34 COMPONENT DESCRIPTIONS (48) Air Flow Proving Switch – (OPT) (All Except Digit 12=9) (STD on units with Digit 12=9) (44) Blower Supply Power Terminal Strip – (STD) The air flow proving switch is factory installed in the duct The terminal strip is labeled to match the electrical wiring furnace electrical junction box.
- Page 35 COMPONENT DESCRIPTIONS For Modine Control System Units Only (Model Digit 12=9) Circuit Analyzer – (OPT) (All Except Digit 12=9) The following items may be included with units configured with the Modine Control System option: (Not Shown in Figure 26.1) The circuit analyzer is factory installed on the door of the electrical section.
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Page 36: General Performance Data
GENERAL PERFORMANCE DATA Table 36.1 - General Performance Data Blower Style/Size Temperature Rise (°F) Model Size Btu/Hr Btu/Hr Minimum Maximum (Digits 4-6) Input j Output j CFM k (Digit 16) Size Maximum Minimum A or B 1800 75,000 60,750 C or D 2813 C or D 3000... - Page 37 GENERAL PERFORMANCE DATA Table 37.1 - Air Temperature Rise jkl Air Temperature Rise Through Unit (°F) Btu/Hr Btu/Hr Model Size Input j Output j 75,000 60,750 2,813 1,406 1,125 100,000 81,000 3,750 1,875 1,500 1,250 1,071 125,000 101,250 4,688 2,344 1,875 1,563 1,339...
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Page 38: Pressure Drop And Blower Performance Data
OPTION & ACCESSORY PRESSURE DROP DATA Table 38.1 - Option & Accessory Pressure Drop Tables (in ''W.C.) All Units Weatherproof Unit Only j Accessory / Option static pressure losses are approximate values only. Please consult the Accuspec selection software for static Unit Size Digit 16 pressure losses at other than... - Page 39 BLOWER PERFORMANCE DATA Table 39.1 - Unit Performance Tables jk Total Static Pressure, ''W.C. 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 Digit Temp. Unit Size Rise BHP RPM BHP RPM BHP RPM RPM BHP RPM BHP RPM BHP RPM BHP 100°F / - 0.09...
- Page 40 BLOWER PERFORMANCE DATA Table 40.1 - Unit Performance Tables jk Total Static Pressure, ''W.C. 0.25 0.50 0.75 1.00 1.25 1.50 2.00 2.50 3.00 Digit Temp. Unit Size Rise BHP RPM BHP RPM BHP RPM BHP RPM 100°F / 120°F 1852 0.26 0.39 0.54...
- Page 41 BLOWER PERFORMANCE DATA Table 41.1 - Unit Performance Tables jk 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 120°F / -...
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Page 42: Blower Sheave Adjustment And Assembly Data
BLOWER SHEAVE ASSEMBLY DATA Adjusting the Blower Drive Sheave Setting Example: All units include a sheave assembly indicated by Digit 19 of the model nomenclature. Within that assembly are the fixed Determine motor sheave turns open for a unit operating at blower sheave, adjustable motor sheave, and belt(s) to provide 4000 CFM with a design external static pressure (ESP) of a method of adjusting the blower speed to balance the airflow... - Page 43 BLOWER SHEAVE ASSEMBLY DATA Table 43.1 - Sheave Assembly Data Blower RPM by Sheave Turns Open Setting (Approx.) Blower Type Sheave Digit 16 Digit 19 RPM Range A, B 656-1001 1001 C, D, E 978-1265 1265 1236 1208 1179 1150 1122 1093 1064...
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Page 44: Unit Dimensions
DIMENSIONS - UNIT Figure 44.1 - DBS Separated Combustion Blower Package Unit Dimensions Qty (4) Drill Locator Dimples for Field Drilled Electrical Conduit Entry Holes (spaced 2.0" apart) 500 - 800 Model Shown Figure 44.2 - DCS Separated Combustion Cooling Package Unit Dimensions 108.94... - Page 45 DIMENSIONS - UNIT Figure 45.1 - DBS Separated Combustion Blower Package Unit Dimensions with Blower Type I, J, K, or L 500 - 800 Model Shown Figure 45.2 - DCS Separated Combustion Cooling Package Unit Dimensions with Blower Type I, J, or K Table 45.1 - Indoor Separated Combustion Unit Dimensions with Blower I, J, K, or L (All dimensions in inches)
- Page 46 DIMENSIONS - UNIT Figure 46.1 - Unit Base Dimensions (TO END OF UNIT) 0.63 2.36 0.75" SUSPENSION HANGING LOCATIONS (TYPICAL 4 CORNERS) RETURN OPENING (OPTIONAL) (Inside) SUSPENSION 24.00 POINT (Inside) SUSPENSION Suspension POINT Point LIFTING POINTt LIFTING POINTt 4.35 1.45 Table 46.1 - Indoor Separated Combustion Blower Package Units (All dimensions in inches) Dimensions Model...
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Page 47: Cooling Coil Dimensions
DIMENSIONS - COOLING COILS Figure 47.1 - DX Coil Drawing - (All dimensions in inches) Rows Airflow Direction TOP VIEW Distributor Inlet (Liquid Line) Connection(s) (Second Inlet on Dual Coil for Right Hand Units Circuit Coils) (Digit 9 = R) Headers on opposite side for Left Hand Units SIDE VIEW... -
Page 48: Weights
WEIGHTS Table 48.1 - Unit Weights j Base Unit Dampers Insulation Double Wall Liners Digit 2 Digit 2 Digit 2 Model Blower Type Fresh Air Fresh & Size (Digit 16) Motor Filters Only Return Air 100/125 150/175 200/225 250/300 E,F,G, or H 250/300 I, J, or K 350/400 E,F,G, or H... -
Page 49: Maintenance
A complete replacement the filters checked monthly. Clean or replace if necessary. In dirty parts list may be obtained by contacting Modine Manufacturing atmospheres, filter maintenance may be required more often. Company. Refer to the rating plate on the appliance for complete appliance model number, serial number, and Figure 49.1 - Filter Replacement Arrangement for... - Page 50 MAINTENANCE Cooling Coil Maintenance Duct Furnace 1. Periodically, inspect the coil for signs of corrosion and leaks. When providing annual maintenance for the duct furnace, keep Repair and replacement of the coil and the connecting piping, the unit free from dust, dirt, grease and foreign matter. Pay valves, etc., must be performed as needed by a qualified particular attention to: technician.
- Page 51 MAINTENANCE Manifold Assembly Removal Burner and Pilot Assembly Removal To remove the manifold (Refer to Figure 51.1) To remove the burner (Refer to Figure 51.2) Shut off gas and electric supply. Shut off gas and electric supply. Disconnect gas manifold at ground union joint. Disconnect the pilot supply line from the gas valve.
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Page 52: Service & Troubleshooting
SERVICE & TROUBLESHOOTING WARNING CAUTION When servicing or repairing this equipment, use only Do not reuse any mechanical or electrical component which factory-approved service replacement parts. A complete has been wet. Such component must be replaced. replacement parts list may be obtained by contacting Modine Manufacturing Company. - Page 53 SERVICE & TROUBLESHOOTING (CONTINUED) Table 53.1 - Troubleshooting (Continued) Trouble Possible Cause Possible Remedy Floating Flames (See Figure 53.1) Insufficient primary air. Increase primary air. Main pressure set too high. Adjust to a maximum of 14” W.C. Orifice too large. Check orifice size with those listed on the serial plate.
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Page 55: Start-Up Checklist
START-UP CHECKLIST START-UP CHECKLIST INDIRECT GAS-FIRED HEATING EQUIPMENT 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. -
Page 56: Model Designations
MODEL DESIGNATIONS Model Identification Figure 56.1 - Serial Plate and Model Identification Plate Locations Modine weatherproof duct furnace/make-up air units contain an ETL/ETL Canada certified weatherproof duct furnace. This duct furnace is combined with either a blower section, or a blower and/or cooling and/or downturn sections to make a complete make-up air or heating/ventilating/cooling unit that is SERIAL... -
Page 57: Model Nomenclature
MODEL NOMENCLATURE FOR SYSTEM UNITS Model Nomenclature 4 5 6 19 20 21 1 - Product Type (PT) 15 - Transformer (TR) D or I - Indoor Indirect Fired Heating & Make-Up Air Unit 1 - 40 VA 4 - 250 VA 2 - 75 VA 0 - None 2 - Unit Configuration (UC) - Page 58 PAGE INTENTIONALLY LEFT BLANK 5-594.10...
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Page 60: Commercial Warranty
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. Modine Manufacturing Company 1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 (HEAT)
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