Modine Manufacturing HBP Installation And Service Manual
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Modine Manufacturing HBP Installation And Service Manual

Indirect gas-fired weatherproof make-up air units
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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.
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.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
INSTALLATION AND SERVICE MANUAL
indirect gas-fired weatherproof make-up air units
THIS MANUAL IS THE PROPERTY OF THE OWNER.
models HBP/HCP/HDP/HPP
OBP/OCP/ODP/OPP
All models approved for use in California by the CEC.
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Open windows.
2. Don't touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
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.

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).
5-572.10
5H0762330001
January, 2020

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  • Page 1: Inspection On Arrival

    5-572.10 5H0762330001 January, 2020 INSTALLATION AND SERVICE MANUAL indirect gas-fired weatherproof make-up air units models HBP/HCP/HDP/HPP OBP/OCP/ODP/OPP All models approved for use in California by the CEC. WARNING FOR YOUR SAFETY 1. Improper installation, adjustment, alteration, IF YOU SMELL GAS: service or maintenance can cause property 1.

  • Page 2: Special Precautions

    BELOW. FAILURE TO PROPERLY ADDRESS THESE replacement parts list may be obtained by contacting CRITICAL AREAS COULD RESULT IN PROPERTY Modine Manufacturing Company. Refer to the rating DAMAGE OR LOSS, PERSONAL INJURY, OR DEATH. plate on the appliance for complete appliance model THESE INSTRUCTIONS ARE SUBJECT TO ANY MORE number, serial number, and company address.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Table of Contents Inspection on Arrival ..............1 Special Precautions ..............2 SI (Metric) Conversion Factors ..........2 Special Design Requests ............4 Storage Prior to Installation ............4 Unit Location ................4 Combustible Material and Service Clearances ....4 Sound and Vibration Levels ............

  • Page 4: Special Design Requests

    SPECIAL DESIGN REQUESTS Figure 4.1 Combustible Material & Service Clearances j Modine Manufacturing Company will sometimes build units with special features as requested by the customer. This manual only covers standard features and does not include any changes made for special feature requests by the customer.

  • Page 5: Sound And Vibration Levels

    SOUND ATTENUATION / ROOF CURB INSTALLATION Curb or Sub-Base Mounted Sites Sound and Vibration Levels An optional roof curb is available to simplify site preparation All mechanical equipment generates some sound and vibration and raise the unit above roof water and snow level for drainage. that may require attenuation.

  • Page 6: Slab Mounting

    SLAB MOUNT INSTALLATION / RIGGING INSTRUCTIONS Slab Mounted Units General Rigging Instructions WARNING For Horizontal Discharge (Model Digit 2=B or C) For ground level installation of a horizontal-discharge unit, prepare a level concrete slab at least four inches thick on Failure to follow proper lifting instructions and applicable adequate footings and a generous bed of gravel for drainage safety procedures could result in property damage, serious...

  • Page 7: Duct Installation/Utility Connections

    DUCT INSTALLATION / UTILITY CONNECTIONS Duct Installation The blower section inlet and/or return air connections, On horizontal discharge units with Model Digit 2=B, provide removable access panels on the downstream side of the as well as the furnace furnace discharge are designed to unit as shown in Figure 7.1.

  • Page 8: Unit Installation

    UNIT INSTALLATION 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 WARNING 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"...
  • Page 9 INSTALLATION Table 9.3 - Burner Orifice Sizing and Gas Consumption Table 9.1 - 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” 1 1∕2” 2”...

  • Page 10: Considerations For Elevation

    INSTALLATION Considerations for Elevation Equation 10.1 - Manifold Pressure for Gas Heating Values Different Than Shown in Table 10.1 The standard ratings for the duct furnace(s) used in these units 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 11: Electrical Connections

    UNIT INSTALLATION Electrical Connections The wire gauge must be sized according to the National Electric Code or CSA code based on amp draw and length WARNING of run. Refer to Table 11.1 for maximum wire lengths that can be wired between components and the terminal block on the unit based on the wire gauge being used.

  • Page 12: Evaporative Cooler

    ELECTRICAL CONNECTIONS Depending on the configuration of the unit controls, Figure 12.1 - Recommended Accessory Field there may be sensors that are field installed. Review the Installed Disconnect Switch Mounting Locations unit ordered to verify that the sensors supplied match the configuration of the unit.
  • Page 13 UNIT INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK 5-572.10...

  • Page 14: Cooling Coil Specifications And Installation

    UNIT INSTALLATION Cooling Coil Units Direct Expansion (DX) Piping The refrigerant lines should be insulated to prevent warming Units with a cooling section (Model Digit 2=C or P) can be or cooling of the refrigerant. If the suction line is allowed to provided with a factory installed direct expansion (DX) coil, a be cooled, liquid will condense in the line and can severely chilled water (water or water/glycol mixtures) coil, or the coil...
  • Page 15 UNIT INSTALLATION Figure 15.1 - General Chilled Fluid Piping is ready to be charged or refrigerant pumped down in another portion of the system can be opened to the coil. A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed.

  • Page 16: Start-Up Procedure

    START-UP PROCEDURE Start-Up Procedure exceed the motor nameplate rating. On three phase systems, check all legs to insure system is balanced. IMPORTANT 19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minimum inlet pressure should be 6"...

  • Page 17: 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 18 START-UP PROCEDURE Check/Adjust Pressure for the Modulating Valve the valve to close too far and lose flame. (continued) Save the setting by simultaneously holding Buttons #1 and #2 until the LED turns OFF. If this is not 11. After the plug is in place, move the field installed manual performed within 5 minutes, the control will default shut-off valve to the “ON”...

  • Page 19: Blower Adjustment

    START-UP PROCEDURE Blower Adjustments 11. Check the motor amps to ensure the maximum motor amp rating is not exceeded. Verify airflow volume and repeat All belt drive supply fan speed adjustments can be made with steps above for further adjustment. the adjustable sheave on the blower motor as follows: 12.

  • Page 20: 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 burner is lit to 100% full fire.

  • Page 21: Variable Air Volume Applications

    START-UP PROCEDURE 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 22: Component/Option Locations

    COMPONENT/OPTION LOCATIONS For location of standard and optional factory installed components, refer to Figure 22.1 and the descriptions on the following pages. Figure 22.1 - Factory Mounted Option Locations 1. Discharge Thermostat (not shown) 2. Low Gas Pressure Switch 3. High Gas Pressure Switch 4.

  • Page 23: 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. Refer to controls and disables the ignition controller and combination Figure 22.1 for the descriptions on the following pages.
  • Page 24 COMPONENT DESCRIPTIONS (6) Ignition Controller – (STD) (14) Control Relay – (OPT) The ignition controller is factory installed in the duct furnace The control relay is factory installed in the blower electrical electrical junction box with the spark ignitor and sensor located section.
  • Page 25 COMPONENT DESCRIPTIONS (17) Step Down Transformer Fuses – (OPT) (22) Return Air Fire Stat – (OPT) The transformer fuses are factory installed in the blower electrical The return air fire stat is factory installed in the blower electrical section. The fuses are included to protect the transformer. section with the sensor in the return air stream.
  • Page 26 COMPONENT DESCRIPTIONS (30) Direct Drive Damper Actuator – (OPT) Adjusting the Damper End Switch: If the damper limiter was adjusted in the previous section, it may be required to The direct drive damper actuator is factory installed on the side adjust the Damper End Switch as follows: of the fresh air damper.
  • Page 27 COMPONENT DESCRIPTIONS (31) Enthalpy Controller – (OPT) (All Except Model Digit 12=9) (34) Proportional Temperature Controller – (OPT) (All An enthalpy controller is provided with Air Control option (Model Except Model Digit 12=9) Digits 20-21=GJ). The purpose of the enthalpy controller is to A proportional temperature controller sensor is provided with use outside air for free cooling, whenever possible, to reduce Air Control options (Model Digits 20-21=GG or GH) and factory...
  • Page 28 COMPONENT DESCRIPTIONS (39) Dirty Filter Switch – (OPT) (37) Convenience Outlet – (OPT) The dirty filter pressure switch is factory installed in the blower electrical section. The switch monitors the pressure differential The convenience outlet is factory installed in the blower section between the two sides of the filters.
  • Page 29 COMPONENT DESCRIPTIONS (40) Motor Starter – (OPT) (41) Mild Temperature Stat – (OPT) (All Except Digit 12=9) The motor starter is factory installed in the blower electrical The mild temperature thermostat is factory installed in the section. A motor starter is required for: blower electrical section.
  • Page 30 COMPONENT DESCRIPTIONS (46) Electronic Modulation Amplifier – (OPT) (50) Supply Air Fire Stat – (OPT) An electronic modulation amplifier is provided factory installed The supply air fire stat is factory installed in the duct furnace in the duct furnace electrical junction box when the unit is electrical junction box with the sensor in the discharge air equip ped with Electronic Modulating Gas Controls (Model Digit stream.
  • Page 31 COMPONENT DESCRIPTIONS (Not Shown) Circuit Analyzer – (OPT) (All Except Digit 12=9) For Modine Control System Units Only (Model Digit 12=9) The circuit analyzer is factory installed on the door of the The following items may be included with units configured with electrical section.

  • Page 32: General Performance Data

    GENERAL PERFORMANCE DATA Table 32.1 - 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 33 GENERAL PERFORMANCE DATA Table 33.1 - 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...

  • Page 34: Pressure Drop Data

    OPTION & ACCESSORY PRESSURE DROP DATA Table 34.1 - Option & Accessory Pressure Drop Tables (in ''W.C.) j Filters Evap Cooler, 12” Media Other Unit Size Digit 16 2” 2” Farr 2” Without With Downturn Rainhood and Discharge Permanent Aeropleat Farr 30/30 Pre-Filters Pre-Filters...

  • Page 35: Blower Performance Data

    BLOWER PERFORMANCE DATA Table 35.1 - 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 16 Rise BHP RPM 100°F / - 0.09 0.15 0.22 1031 0.29 1170 0.37 1296 0.45...
  • Page 36 BLOWER PERFORMANCE DATA Table 36.1 - 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 16 Rise BHP RPM 1852 0.26 0.39 0.54 0.69 0.85 1.03 1074 1.39 1239 1.79 1387...
  • Page 37 BLOWER PERFORMANCE DATA Table 37.1 - 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 / -...

  • Page 38: Blower Sheave 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 39 BLOWER SHEAVE ASSEMBLY DATA Table 39.1 - 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...

  • Page 40: Dimensions

    DIMENSIONS - UNIT Figure 40.1 - Outdoor STANDARD Blower Package Unit (Model Digit 2=B, Digit 16=A through H) 500 - 800 Model Shown 33.50 33.50 48.00 Qty (4) Drill Locator Dimples for Field Drilled Electrical Optional Rainhood Conduit Entry Holes 2.32 P (OVER ROOF) &...
  • Page 41 DIMENSIONS - UNIT Figure 41.1 - Outdoor EXTENDED Blower Package Unit (Model Digit 2=B, Digit 16=I, J, K, or L) 500 - 800 Model Shown 47.27 36.58 P (OVER ROOF) BLOWER CABINET ROOF EXTENSION (”L” BLOWERS ONLY) OPTIONAL RAINHOOD 2.32 &...
  • Page 42 DIMENSIONS - UNIT Figure 42.1 - Outdoor STANDARD Blower Cooling Package Unit (Model Digit 2=C, Digit 16=A through H) 105.49 24.00 33.50 48.00 QTY (4) DRILL LOCATOR DIMPLES OPTIONAL RAINHOOD FOR FIELD DRILLED ELECTRICAL & BIRDSCREEN CONDUIT ENTRY HOLES P (OVER ROOF) (SPACED 2.0"...
  • Page 43 DIMENSIONS - UNIT Figure 43.1 - Outdoor EXTENDED Blower Cooling Package Unit (Model Digit 2=C, Digit 16=I, J, K, or L) 141.34 24.00 33.50 47.27 36.58 QTY (4) DRILL LOCATOR DIMPLES FOR FIELD DRILLED ELECTRICAL CONDUIT ENTRY HOLES OPTIONAL RAINHOOD (SPACED 2.0"...
  • Page 44 DIMENSIONS - UNIT BASE Figure 44.1 - Unit Base Dimensions To end of Unit 6.28 Drill Locator Dimple for Field Drilled Gas Inside Connection Entry Hole Inside Left Hand Access Units Drill Locator Dimple 6.28 for Field Drilled Gas Connection Entry Hole Right Hand Access Units Return Air Opening...
  • Page 45 DIMENSIONS - ROOF CURBS Figure 45.1 - Roof Curb Dimensions DISCHARGE AIR OPENING FOR UNITS WITH MODEL DIGIT 2= D OR P ONLY Table 45.1 - Roof Curb Dimensions Model Digit 2=B or D (All dimensions in inches) Dimensions Model Blower Type Digit 2=B Digit 2=D...
  • Page 46 DIMENSIONS - COOLING COILS Figure 46.1 - DX Coil Drawing (All dimensions in inches) Airflow Direction Rows 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 FRONT VIEW...
  • Page 47 DIMENSIONS - RAINHOOD, REMOTE PANEL & EVAPORATIVE COOLER Table 47.1 - Rainhood and Birdscreen Figure 47.1 - Rainhood and Birdscreen Dimensions Dimensions (inches) 1.14 1.14 42.66 Approx. 1.09 Rainhood & Birdscreen Model Size 29.43 100/125 31.94 150/175 38.24 31.19 32.71 200/225 38.24 44.56...

  • Page 48: Weights

    WEIGHTS Table 48.1 - Unit Operating Weights j Base Unit Dampers Double Wall (all sections) Digit 2 Digit 2 Model Blower Type Rain- Evap Fresh Air Fresh & Size (Digit 16) Motor Filters hood Cooler Only Return Air 100/125 150/175 200/225 250/300 E,F,G, or H 250/300...
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  • Page 50: Maintenance

    A complete replacement the filters checked monthly. Clean or replace if necessary. In dirty parts list may be obtained by contacting Modine Manufacturing Company. Refer to the rating plate on the appliance for atmospheres, filter maintenance may be required more often.
  • Page 51 MAINTENANCE Cooling Coil Maintenance Duct Furnace Periodically, inspect the coil for signs of corrosion When providing annual maintenance for the duct furnace, keep and leaks. Repair and replacement of the coil and the the unit free from dust, dirt, grease and foreign matter. Pay connecting piping, valves, etc., must be performed as particular attention to: needed by a qualified technician.
  • Page 52 MAINTENANCE Burner and Pilot Assembly Removal Manifold Assembly Removal To remove the burner (Refer to Figure 52.2): To remove the manifold (Refer to Figure 52.1): Shut off gas and electric supply. Shut off gas and electric supply. Disconnect the pilot supply line from the gas valve. Remove the side access panel.
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  • Page 54: 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 55 SERVICE & TROUBLESHOOTING (CONTINUED) Table 54.1 - Troubleshooting (Continued) Trouble Possible Cause Possible Remedy Floating Flames (See Figure 55.1) 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 57: 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 58: Model Designations

    MODEL DESIGNATIONS Model Identification Figure 58.1 - Serial Plate & Model ID 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 ETL/ETL Canada certified.

  • Page 59: Model Nomenclature

    MODEL NOMENCLATURE FOR SYSTEM UNITS Weatherproof Model Nomenclature 4 5 6 19 20 21 1 - Product Type (PT) 15 - Transformer (TR) H or O - Outdoor HVAC Unit 1 - 40 VA 4 - 250 VA 2 - 75 VA 0 - None 2 - Unit Configuration (UC) 3 - 150 VA...

  • 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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