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gas-fired indoor power vented duct furnace/make-up air units
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.
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
All models approved for use in California by the CEC
THIS MANUAL IS THE PROPERTY OF THE OWNER.
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).
5-565.1
5H080644a
November, 2009
models dBP/dcP
9900100
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Summary of Contents for Modine Manufacturing DBP
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Page 1: Inspection On Arrival
5-565.1 5H080644a November, 2009 installation and service manual gas-fired indoor power vented duct furnace/make-up air units models dBP/dcP 9900100 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. -
Page 2: Table Of Contents
Maintenance ........48 parts list may be obtained by contacting Modine Manufacturing Service &... -
Page 3: Si (Metric) Conversion Factors
si (metric) conversion factors / unit location figure 3.1 - combustible material and service si (metric) conversion factors clearances table 3.1 to convert multiply By to obtain to convert multiply By to obtain "W.C. 0.24 1.699 /min Btu/ft 3 psig 6.893 0.0374 mJ/m... -
Page 4: Unit Lifting And Unit Mounting
Use a spirit level to ensure that the unit is suspended or floor mounted correctly. unit suspension model Blower type dBP units dcP units all units dBP units 3/4" diameter suspension hanging locations are provided in size (digit 16) the base rail assembly of the unit. -
Page 5: Duct Installation
duct installation Blower section and cooling cabinet discharge duct duct installation connections furnace discharge duct connection The blower section back and bottom and cooling cabinet 1. The furnace discharge is designed to accept straight section discharge are designed to accept 90° flanged ductwork. ductwork. -
Page 6: Venting
installation venting 7. Avoid venting through unheated space. When venting does WARNING 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 1. - Page 7 installation additional requirements for Horizontally vented figure 7.1 - vertical category i vent system 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 LISTED TERMINAL acceptable.) Wrap tape two full turns around the vent pipe.
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Page 8: Unit Installation
unit installation gas connections 1/2". Table 8.1 allows for a 0.3" W.C. pressure drop in the supply pressure from the building main to the unit. The inlet WARNING pressure to the unit must be 6-7" W.C. for natural gas and 11-14"... -
Page 9: Electrical Connections
unit installation unit installation electrical connections figure 9.1 - recommended accessory field installed disconnect switch mounting locations WARNING 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. -
Page 10: Cooling Coil Specifications And Installation
unit installation unit installation direct expansion (dX) Piping The cooling section includes a full coverage, 3-way sloping 409 stainless steel drain pan to remove condensate from coil The refrigerant lines should be insulated to prevent warming headers, thermal expansion valves, and refrigerant piping. or cooling of the refrigerant. - Page 11 unit installation table 11.1 - cooling coil Performance limits dX - single circuit dX - dual circuit chilled Water max. cooling tons ② ③ model coil area coil area coil area chilled size (all units) ➀ (sq. ft.) cfm ➀ (sq.
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Page 12: Start-Up Procedure
unit installation / start-uP Procedure operation start-up Procedure IMPORTANT general - all coils Proper air distribution is vital to coil performance. Air flow anywhere on the coil face should not vary by more than 1. To prevent premature heat exchanger failure, observe heat 20%. -
Page 13: Pilot Burner And Main Burner Adjustment
unit installation / start-uP Procedure main Burner adjustment 19. Recheck the gas supply pressure at the field installed manual shut-off valve. The minumum inlet pressure should The gas pressure regulator (integral to the combination gas be 6" W.C. on natural gas and 11" W.C. on propane gas. control) is adjusted at the factory for average gas conditions. - Page 14 start-uP Procedure figure 14.1 - checking manifold Pressure with heat exchanger support locations.) To decrease primary air, “u” tube manometer move the air shutters away from the manifolds until flames no longer lift from burner ports, but being careful not to cause yellow tipping.
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Page 15: Blower Adjustment
start- uP Procedure damper linkage adjustment Blower adjustments If blower fan speed changes are required, adjust motor sheave If the unit is provided with a return air damper, to prevent as follows: shipping damage, the return air damper linkage is disconnected and the damper closed. - Page 16 start-uP Procedure single-stage gas controls (intermittent pilot) modulating gas valve in one of ten positions. A hydrostatic sensing bulb located in the discharge air stream controls the gas Utilizes a single-stage combination gas control, an ignition flow between 40% through 100% full fire. When the discharge control, and a single-stage low voltage thermostat.
- Page 17 start-uP Procedure main burner. As the temperature drops, the voltage drops input signal between either 0-10 Vdc or 4-20 mA (The causing the modulating valve to open further. If the discharge signal conditioner can accept a 0-10 Vdc signal when all air temperature increases, the voltage increases causing the the dip switches are in the “OFF”...
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Page 18: Options
oPtions options - factory installed figure 18.1 - factory mounted option locations 51 55 Units with Premium Control Box 1. Discharge Thermostat 19. Factory Installed Minimum Positioner 37. Convenience Outlet 2. Low Gas Pressure Switch 20. Extended Grease Line Zerk Fittings 38. - Page 19 oPtions (2) low gas Pressure switch – (oPt) b) Two-stage Electronic Type Thermostat - Includes a The low gas pressure switch is factory installed in the duct factory installed discharge air sensor. The thermostat furnace above the gas train. The switch monitors the gas body is field installed remotely and includes the discharge pressure upstream of all the gas controls and shuts off the air set point adjuster that must be field set.
- Page 20 oPtions (6) ignition controller – (oPt) (16) dead front disconnect switch – (oPt) The ignition controller is factory installed in the duct furnace WARNING electrical junction box with the spark ignitor and sensor located on the burner. For both natural and propane gas units, the ignition controller When the dead front disconnect switch is in the “OFF”...
- Page 21 oPtions (20) extended grease line Zerk fittings – (oPt) provided, is controlled by the damper linkage between the two The extended grease line zerk fittings are factory installed on the dampers. All damper actuators are low voltage (24V). For Right exterior corner post between the electrical and blower sections.
- Page 22 oPtions The enthalpy controller is used in conjunction with the Enthalpy Modulating Damper Actuator: A modulating damper actuator is Sensor (not shown and field installed) and a mixed air temper- provided with Air Control options GA, GB, GC, GD, GE, GF, GG, ature sensor (not shown).
- Page 23 oPtions Outdoor Enthalpy Changeover Set Point section door on the access side of the unit. When the blower The outdoor enthalpy changeover set point returns the outdoor section door is removed, the momentary switch is released and air damper to the minimum position when the enthalpy rises interrupts power to the low voltage circuit.
- Page 24 oPtions (40) motor starter – (oPt) figure 24.2 - Proportional temperature controller 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 SET POINT point dial is factory set to the motor full load amp draw listed on DIAL...
- Page 25 oPtions (47) electronic modulating gas valve – (oPt) (55) differential Pressure switch An electronic modulating gas valve is provided factory installed A differential pressure switch is supplied on all power vented in the duct furnace gas train when the unit is equipped with duct furnaces and is designed to prevent operation of the main Electronic Modulating Gas Controls (Digit 12 = 4, 5, 6, 7, or 8).
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Page 26: General Performance Data
general Performance data table 26.1 - general Performance data - models With Blower model size (digits 4-6) Btu/Hr input ➀ 75,000 10,0000 125,000 150,000 175,000 Btu/Hr output 60,000 80,000 100,000 120,000 140,000 ➀ Blower style (digit 16 letter) A or B C or D C or D E or F... - Page 27 general Performance data table 27.1 - air temperature rise Btu/Hr air temperature rise through unit (°f) ➀ input output ➁ 75,000 60,000 2778 2222 1852 1587 1389 1235 1111 1010 100,000 80,000 3704 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 125,000...
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Page 28: Unit Selection
Model Nomenclature on page 55, the Model Configuration (filters or dampers). and Venting = DBP. The unit configuration is determined by the location 2. determine the furnace input rating (mBH): where the unit is to be installed. The critical options and... - Page 29 For 11. determine the transformer: purposes of this selection, a motor starter by others will be For DBP/DCP models, a 75VA Transformer is required. used so the Motor Horsepower = G. Thus, the Transformer = 2.
- Page 30 oPtion & accessory Pressure droP data table 30.1 - option & accessory Pressure drop tables (in ''W.c.) ➀ all units Weatherproof unit only unit size digit 16 0.01 0.01 0.02 0.03 0.01 0.05 0.02 0.07 0.00 0.01 0.00 0.01 0.01 0.02 0.03 0.01...
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Page 31: Blower Performance Data
BloWer Performance data table 31.1 - unit Performance tables ➀ ➁ 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 BHP rPm BHP rPm BHP rPm BHP rPm BHP rPm BHP rPm BHP rPm BHP rPm 100°F / - 0.09 0.15... - Page 32 BloWer Performance data table 32.1 - unit Performance tables ➀ ➁ 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 BHP rPm BHP rPm BHP rPm BHP rPm rPm BHP rPm BHP rPm BHP rPm 100°F / 120°F...
- Page 33 BloWer Performance data table 33.1 - unit Performance tables ➀ ➁ 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 34: Blower Sheave Assembly Data
BloWer sHeave assemBly data adjusting the Blower drive setting Locate the unit Model Identification Plate and note Digit 16 and Digit 19 of the model number. Digit 16 is the Blower Size and Type and Digit 19 is the Sheave Arrangement. Based on the Sheave Arrangement, Tables 34.1 through 35.5 give the Sheave Assembly numbers used on units that include a Once the Blower Size and Type (Digit 16) is known, enter... - Page 35 BloWer sHeave assemBly data Blower sheave assembly numbers (con’t) 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 Digit 19 Sheave Assembly 3H35127B1 3H35127B2 3H35127B3...
- Page 36 BloWer sHeave assemBly data table 36.1 - Blower sheave assembly settings turns open sheave assembly Blower rPm 3H35125B1-2 1001 966 3H35125B3-5 1265 1236 1208 1179 1150 1121 1093 1064 1035 1006 978 3H35125B6-7 1561 1520 1479 1438 1396 1355 1314 1273 1232 1191 1150 3H35125B8-9 1858 1825 1791 1758 1725 1692 1659 1625 1592 1559 1526 3H35125B10-11...
- Page 37 BloWer sHeave assemBly data table 37.1 - Blower sheave assembly numbers and size motor sheave Blower sheave motor sheave Blower sheave sheave Browning sheave Browning Pitch Pitch Pitch Pitch assembly Belt no. assembly Belt no. diameter Bore diameter Bore diameter Bore diameter Bore...
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Page 38: Electrical Data
electrical data / motor data 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. Unit Amp Draw (Table 38.1) Motor Amp Draw (Tables 38.2 to 42.1) Total Amp Draw... -
Page 39: Motor Data
motor data table 39.1 - motor data for digit 14 = c - 230v/60Hz/1Ph digits motor motor frame amp. service thermal Weight efficiency 17&18 size (HP) type ➀ size draw factor overload (lbs) ➁ (%) 1.35 TENV 1.00 1.20 TEFC 1.15 1.25 TEFC... - Page 40 motor data table 40.1 - motor data for digit 14 = e - 230v/60Hz/3Ph ① motor motor digits size motor frame amp. service Weight efficiency digits size motor frame amp. service Weight efficiency 17&18 (HP) type ➁ size draw factor (lbs) 17&18 (HP) type ➁...
- Page 41 motor data table 41.1 - motor data for digit 14 = f - 460v/60Hz/3Ph ➀ motor motor digits size motor frame amp. service Weight efficiency digits size motor frame amp. service Weight efficiency 17&18 (HP) type ➁ size draw factor (lbs) (% ) 17&18...
- Page 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 TEFC 1.15 B1 or m1 1.25 B5 or m5 TEFC...
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Page 43: Dimensions Unit
BOTTOM ELECTRICAL CONNECTION 2.00 KNOCKOUTS (ACCESS SIDE ONLY) KNOCKOUTS, IDENTICAL SIZE AS SIDE 1.98 CONNECTIONS (ONLY ON ACCESS SIDE) 116.98 table 43.1 - dBP/dcP indoor Power vented unit dimensions (all dimensions in inches) dimensions model Blower type Qty. of size (digit 16) furnaces conn. - Page 44 - unit figure 44.1 - dBP indoor Power vented Blower Package unit dimensions with Blower type i, J, K, or l 147.59 36.68 30.48 30.07 50.37 OVER ROOF 41.62 29.74 6.44 6" VENT 2.17 CONNECTOR 1.36 34.00 34.00 23.07 (HEIGHT) 24.00...
- Page 45 dimensions - Base figure 45.1 - unit Base dimensions C To end of unit 0.63 0.75" Suspension 2.36 Hanging Locations (Typical 4 Corners) E Inside Suspension 24.00 Inside Point Suspension Point Lifting Lifting Point Point Return Air 4.35 Opening 1.45 table 45.1 - indoor Power vented Blower Package units (all dimensions in inches) dimensions model...
- 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...
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Page 47: Weights
dimensions/WeigHts figure 47.1 - remote Panel dimensions table 47.3 - remote Panel dimensions (all dimensions in inches) remote Panel type Light and Switch Panels Only 7.06 2.81 1.50 Light and Switch Panels with Single Stage 10.60 3.53 4.58 Thermostat or Electronic Set Point Adjustor Light and Switch Panels with 13.09 6.03... -
Page 48: Maintenance
When servicing or repairing this equipment, use only factory- approved service replacement parts. A complete replacement NON-ACCESS NON-ACCESS parts list may be obtained by contacting Modine Manufacturing SIDE SIDE FILTER Company. Refer to the rating plate on the appliance for... - Page 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 the bushing in the bottom of the electrical junction box.
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Page 50: Service & Troubleshooting
service & trouBlesHooting table 50.1 - troubleshooting trouble Possible cause Possible remedy Power exhauster motor will not start 1. Power supply is off. 1. Turn on main power. 2. No 24V power to thermostat. 2. Check control transformer. 3. Thermostat malfunction. 3. - Page 51 service & trouBlesHooting trouble Possible cause Possible remedy not enough Heat 1. Unit cycling on high limit.➀ a. Clean/correct duct system. a. Obstructions/leaks in duct system. b. Adjust to a maximum of 14" W.C. b. Main pressure set too high. c.
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Page 52: Model Designations
Plate is used to identify the complete model, plate (See Figure 53.1). For a complete description of the model including blower and cooling sections. number, see Model Identification. figure 52.1 - serial Plate Modine Manufacturing Company 1500 DeKoven Ave., Racine, WI 53403 Phone: 800.828.4328 Access Slide D"... - Page 53 53.1 - model identification Plate DBP 75AFRHN10A1AA1AAA1A 01101010109-0002 115/208-230 6.6/3.0-3.3 9F20218 5H63081-20 5H76183-31 5H71790- 5H58064-3 8.47 10.00 Modine Manufacturing Company 1500 DeKoven Ave., Racine, WI 53403 Phone: 800.828.4328 figure 53.2 - serial number designation figure 53.3 - serial number designations...
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Page 54: 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. Unit installed level and secure? ____ Yes ___ No 3. -
Page 55: Model Nomenclature
model nomenclature for system units indoor duct furnace model nomenclature 4 5 6 19 20 21 16 - Blower size & Bearing type (BB) 1 - Product type (Pt) A - 9-7 Spider Bearings G - 15-15 Spider Bearings I - Indoor HVAC Unit B - 9-7 Pillow Block Bearings H - 15-15 Pillow Block Bearings 2 - unit configuration (uc) -
Page 56: 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. commercial Products group Modine Manufacturing Company 1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 (HEAT)
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