Modine Manufacturing DBG Manual

5-565.6
5H0806440001
INSTALLATION AND SERVICE MANUAL
indirect gas-red indoor power vented make-up air units
Models DBP/DCP
IBP/ICP
December, 2023
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
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. To prevent premature heat exchanger failure,
do not locate ANY gas-red appliances
in areas where corrosive vapors (i.e.
chlorinated, halogenated or acid) are present
in the atmosphere.
AVERTISSEMENT
1. Une installation, un réglage, une altération,
une réparation ou une maintenance
impropre risque de causer des dommages,
des blessures ou la mort, et d’engendrer
une exposition à des substances dont
certains États ont déterminé qu’elles
étaient cancérogènes ou pouvaient causer
des malformations à la naissance et des
problèmes de reproduction. Lisez bien les
instructions d’installation, d’utilisation et de
maintenance avant d’installer ou de réparer
cet appareil.
AVERTISSEMENT
2. Pour éviter la panne prématurée de
l’échangeur thermique, ne placez AUCUN
appareil à gaz à des endroits où les vapeurs
corrosives (chlorées, halogénées ou acides)
sont présentes dans l’atmosphère.
.
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Open windows.
2. Do not try to light any appliance.
3. Don’t touch electrical switches.
4. Extinguish any open flame.
5. Immediately call your gas supplier.
POUR VOTR E SÉCURITÉ
Si vous sentez une odeur de gaz:
1. Ouvrez les fenêtres.
2. Ne tentez d'allumer aucun autre appareil.
3. Ne touchez pas aux interrupteurs
électriques.
4. Éteignez toute flamme nue.
5. Appelez immédiatement votre compagnie de
gaz.
Model without Cooling Coil Cabinet
Model with Cooling Coil Cabinet
Models Approved For Use In California By The CEC

25-565.6
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.
POUR VOTR E SÉCURITÉ
L'utilisation et le stockage d'essence ou
d'autres vapeurs et liquides inflammables
dans des récipients ouverts à proximité de cet
appareil sont dangereux.
IMPORTANT
1. The use of this manual is specically
intended for a qualied installation and
service agency. A qualied installation and
service agency must perform all installation
and service of these appliances.
2. This appliance is not intended for use by
persons (including children) with reduced
physical, sensory, or mental capabilities,
or lack of experience and knowledge,
unless they have been given supervision or
instruction concerning use of the appliance
by a person responsible for their safety.
3. Children should be supervised to ensure
that they do not play with the appliance.
IMPORTANT
1. Ce manuel est spéciquement destiné
au personnel d’une entreprise qualiée
d’installation et d’entretien. Toutes les
opérations d’installation et d’entretien
doivent être conées à une entreprise
qualiée.
2. Cet appareil n’est pas conçu pour être
utilisé ou entretenu par des personnes (y
compris des enfants) dont les capacités
physiques, sensorielles ou mentales sont
réduites, ou qui n’ont pas l’expérience et les
connaissances su󰀩santes, à moins d’être
supervisées ou d’avoir obtenu des directives
concernant l’utilisation de l’appareil par une
personne responsable de leur sécurité.
3. Les enfants doivent être supervisés
pour s’assurer qu’ils ne jouent pas avec
l’appareil.
TABLE OF CONTENTS
Special Precautions .............................................................3
Hazard Intensity Levels ........................................................3
SI (Metric) Conversion Factors ............................................6
Storage Prior To Installation .................................................6
Unit Location ........................................................................6
Location Recommendations ..............................................6
Unit Mounting Methods ........................................................8
Unit Suspension .................................................................8
Floor Mounted Units ...........................................................8
Unit Lifting ..........................................................................10
Installation ..........................................................................11
Duct Connection to Unit ...................................................11
Utility Connections ...........................................................11
Venting ...............................................................................12
General Venting Instructions ...........................................12
Gas Connections ...............................................................14
Manifold Pressure Adjustment ...........................................17
Electrical Connections .......................................................18
Start-Up Procedure ............................................................22
Pilot Burner Adjustment ...................................................22
Main Burner Adjustment ...................................................23
Air Shutter Adjustment .....................................................25
Blower Adjustments .........................................................25
Lubrication Recommendations ........................................25
Damper Linkage Adjustment ............................................25
Control Operating Sequence ...........................................26
VAV Airow Limits ............................................................27
Component Locations ........................................................28
Component Descriptions ....................................................29
General Performance Data ................................................36
Option & Accessory Pressure Drop Data ...........................38
Blower Performance Data ..................................................39
Blower Sheave Assembly Data ..........................................42
Adjusting the Blower Drive Setting ...................................42
Dimensions - Unit ...............................................................44
Dimensions - Base .............................................................46
Dimensions - Cooling Coils ................................................47
Weights ..............................................................................48
Maintenance ......................................................................49
Cooling Coil Maintenance ................................................50
Duct Furnace ...................................................................50
Gas Piping & Controls ......................................................51
Manifold Assembly Removal ............................................51
Burner and Pilot Assembly Removal ................................51
Service & Troubleshooting .................................................52
Start-Up Checklist ..............................................................56
Model Designations ...........................................................57
Model Identication ..........................................................57
Replacement Parts Ordering ...........................................57
Model Nomenclature For System Units .............................58
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 received for conformance with description of
product ordered (including specications where applicable)

3
5-565.6
SPECIAL PRECAUTIONS
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.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in death or serious
injury.
3. CAUTION: Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or moderate
injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
PRÉCAUTIONS PARTICULIÈRES
LES INSTRUCTIONS D'INSTALLATION ET D'ENTRETIEN DE
CE MANUEL DOIVENT ÊTRE OBSERVÉES POUR ASSURER
UN FONCTIONNEMENT SÉCURITAIRE, EFFICACE ET
FIABLE. DE PLUS, LES PRÉCAUTIONS PARTICULIÈRES CI-
APRÈS DOIVENT ÊTRE RIGOUREUSEMENT RESPECTÉES.
SINON, IL Y AURAIT RISQUE DE DÉGÂTS MATÉRIELS
OU DE PERTE, DE BLESSURE PERSONNELLE OU DE
MORT D'HOMME. CES INSTRUCTIONS SONT SUJETTES
À TOUTE DISPOSITION PLUS RESTRICTIVE DES CODES
PROVINCIAL OU NATIONAL.
HIÉRARCHIE DES NIVEAUX DE RISQUES
1. DANGER : Indique un danger imminent qui, s'il n'est pas
évité, entraînera INÉVITABLEMENT des blessures graves,
voire mortelles.
2. AVERTISSEMENT : Indique un danger potentiel qui, s'il
n'est pas évité, RISQUE d'entraîner des blessures graves,
voire mortelles.
3. ATTENTION : Indique un danger potentiel qui, s'il n'est
pas évité, PEUT entraîner des blessures mineures ou
modérées.
4. IMPORTANT : Indique une situation qui, si elle se
matérialise, PEUT entraîner des risques pour la sécurité
des personnes.
DANGER
Appliances must not be installed where they may be exposed to
potentially explosive or ammable atmosphere.
DANGER
Les appareils ne doivent pas être installés à un endroit où ils
risquent d’être exposés à une atmosphère potentiellement
explosive ou inammable.
WARNING
1. To prevent premature heat exchanger failure, do not locate
ANY gas-red appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the
atmosphere.
2. 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 qualied
rigging company. Use ALL lifting points. Test lift to ensure
proper balance and rigging.
3. Gas red heating equipment must be vented - do not
operate unvented.
4. Units have a built-in power exhauster - additional external
power exhausters are not required or permitted.
5. If you are replacing an existing heater, it may be necessary
to resize the venting systems. Improperly sized venting
systems can result in vent gas leakage or the formation of
condensate. Refer to the National Fuel Gas Code ANSI
Z223.1 or CSA B149.1 latest edition. Failure to follow these
instructions can result in injury or death.
6. Under no circumstances should two sections of double
wall vent pipe be joined together within one horizontal vent
system due to the inability to verify complete seal of inner
pipes.
7. All eld gas piping must be pressure/leak tested prior to
operation. Never use an open ame. Use a soap solution
or equivalent for testing.
8. Gas pressure to appliance controls must never exceed 3.4
kPa (14" W.C. or 1/2 psi).
9. To reduce the opportunity for condensation, the minimum
sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
10. Disconnect power supply before making wiring connections
or working on this equipment. Follow all applicable safety
procedures to prevent accidental power up. Failure to do
so can result in injury or death from electrical shock or
moving parts and may cause equipment damage.
11. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
di󰀨erent from the wiring diagram could result in a hazard to
persons and property.
12. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than the
rated voltage.
13. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
14. When servicing or repairing this equipment, use only
factory-approved service replacement parts. A complete
replacement parts list may be obtained by contacting Modine
Manufacturing Company. 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 owners risk.

45-565.6
SPECIAL PRECAUTIONS
AVERTISSEMENT
1. Pour éviter la panne prématurée de l’échangeur thermique,
ne placez AUCUN appareil à gaz à des endroits où les
vapeurs corrosives (chlorées, halogénées ou acides) sont
présentes dans l’atmosphère.
2. Le non-respect d’une bonne procédure de levage et des
procédures de sécurité qui s’appliquent pourrait mener à
des dommages matériels ou à des blessures graves, voire
mortelles. Le levage doit être e󰀨ectué uniquement par une
entreprise spécialisée dans le gréage. Utilisez TOUS les
points de levage. Testez le levage pour assurer un bon
équilibre et un bon gréage.
3. Les équipements de chau󰀨age au gaz doivent avoir un
système de ventilation – ne les faites pas fonctionner sans
évacuation des gaz
4. Les unités sont munies d’un extracteur électrique intégré
– des extracteurs électriques externes supplémentaires ne
sont pas requis ni permis.
5. Si vous remplacez un appareil de chau󰀨age existant, vous
aurez peut-être à modier les systèmes de ventilation. Des
systèmes de ventilation de diamètre insu󰀩sant peuvent
causer des fuites de gaz ou la formation de condensat.
Reportez-vous au code National Fuel Gas ANSI Z223.1 ou
à la dernière édition de la norme CSA B149.1. Le non-
respect de ces directives pourrait entraîner des blessures
graves, voire mortelles.
6. Il est interdit d’accoupler deux longueurs de tuyau à double
paroi dans une même installation d’évacuation horizontale
étant donné l’impossibilité de vérier l’étanchéité des
raccords du tuyau intérieur.
7. Toutes les canalisations de gaz sur site doivent être
testées (pression/fuites) avant usage. Ne recherchez
jamais les fuites avec une amme nue. Utilisez plutôt de
l’eau savonneuse ou un produit équivalent.
8. La pression de gaz aux commandes de l’appareil ne doit
jamais dépasser 3.4 kPa (35,5 cm C.E. ou 1/2 psi).
9. Pour réduire le risque de condensation, l’entrée minimum
dans l’appareil au niveau de la mer, telle qu’indiquée sur la
plaque de série, ne doit pas être moins de 5 % inférieure à
la valeur d’entrée nominale des appareils à double valeur
nominale.
10. Débranchez l’alimentation électrique avant d’e󰀨ectuer
des connexions ou de travailler sur l’appareil. Respectez
toutes les procédures de sécurité qui s’appliquent pour
éviter toute mise en marche accidentelle. Le non-respect
de cette directive peut entraîner des blessures ou la mort
causées par un choc électrique ou des pièces mobiles, en
plus d’endommager l’appareil.
11. Tous les appareils doivent être branchés de manière
strictement conforme au diagramme fourni. Tout câblage
di󰀨érent de celui du schéma peut créer des risques de
dommages matériels ou de blessures.
12. Assurez-vous que la tension d’alimentation de l’appareil,
comme indiqué sur la plaque de série, n’est pas de 5 %
supérieure à la tension nominale.
13. Tout câblage usine d’origine exigeant un remplacement
doit être remplacé par un câble d’indice thermique nominal
de 105 °C.
14. Pour l’entretien et les réparations de cet appareil, utilisez
uniquement des pièces d’origine certiées. Pour la liste
complete des pièces de rechange, consultez Modine
Manufacturing Company. Le numéro de modèle complet,
le numéro de série et l’adresse du fabricant gurent sur la
plaque signalétique xée à l’appareil. Toute substitution de
pièce ou decommande non approuvée par le fabricant sera
aux risques du propriétaire.
CAUTION
1. Purging of air from gas supply line should be performed
as described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
2. Do not reuse any mechanical or electronic ignition
controllers which has been wet. Replace defective
controller.
3. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
ATTENTION
1. La purge de l’air des tuyauteries de gaz doit se faire selon
la procédure ANSI Z223.1 de la dernière édition du «
National Fuel Gas Code » ou des codes CAN/CGA-B149
du Canada.
2. Les équipements de chau󰀨age au gaz doivent avoir un
système de ventilation – ne les faites pas fonctionner sans
évacuation des gaz.
3. Vériez que la tension d’alimentation de l’appareil n’est pas
inférieure de plus de 5 % à la tension nominale inscrite sur
la plaque de série.

5
5-565.6
SPECIAL PRECAUTIONS
IMPORTANT
1. For installation only in locations not accessible to the
general public.
2. Unit can be operated up to a maximum of 10,000 feet
(3048 m).
3. To prevent premature heat exchanger failure, the input to
the appliance, as indicated on the serial plate, must not
exceed the rated input by more than 5%.
4. To prevent premature heat exchanger failure, observe heat
exchanger tubes by looking at the heat exchanger through
the eld installed access openings in connecting ductwork
in cooling package units or the unit access doors in blower
package units. If the bottom of the tubes become red
while blower and duct furnace are in operation, check to
be sure the blower has been set to the proper rpm for the
application. Refer to page 25 for Blower Adjustments.
5. Start up and adjustment procedures, installation, and
service of these appliances must be performed by a
qualied installation and service agency.
6. To prevent premature heat exchanger failure, with all
control systems, a blower starting mechanism must be
provided so that the blower is running or energized within
45 seconds of the gas control operation.
7. To check most of the Possible Remedies in the
troubleshooting guide listed in Table 52.1, refer to the
applicable sections of the manual.
IMPORTANT
1. Pour installation uniquement dans des endroits non
accessibles au public.
2. L’unité peut être utilisée jusqu’à un maximum de 3048 m
(10,000 ft).
3. Pour éviter une défaillance prématurée de l’échangeur de
chaleur, le pouvoir calorique du gaz utilisé ne doit pas
excéder de plus de 5 % la valeur nominale inscrite sur la
plaque signalétique de l’appareil.
4. Pour éviter la défaillance prématurée de l’échangeur de
chaleur, examinez les tubes de l’échangeur de chaleur en
le regardant à travers les ouvertures d’accès installées
sur les lieux lors de la connexion des tuyaux ou les portes
d’accès à l’unité où il est possible de voir l’échangeur
de chaleur. Si le bas des tubes devient rouge lorsque
la sou󰀪ante et la chaudière canalisée sont en marche,
vériez que le régime de la sou󰀪ante est approprié pour
l’application. Pour le réglage de la sou󰀪ante, reportez-
vous à la page 25.
5. Les procédures de démarrage et de réglage, l’installation
et le service de ces appareils doivent être conés à un
centre d’installation et de service qualié.
6. Pour éviter la panne prématurée de l'échangeur thermique,
avec tous les systèmes de commande, un mécanisme
de démarrage de la sou󰀪erie doit être fourni pour que
la sou󰀪erie démarre dans les 45 secondes qui suivent
l'activation de la commande de gaz.
7. Pour essayer la plupart des solutions possibles suggérées
dans le guide de dépannage du Table 52.1 reportez-vous
aux sections correspondantes du manuel

65-565.6
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION
Table 6.1 - SI (Metric) Conversion Factors
To
Convert Multiply By
To
Obtain
To
Convert Multiply By
To
Obtain
"W.C. 0.24 kPa CFH 1.699 m³/min
psig 6.893 kPa Btu/ft³ 0.0374 mJ/m³
°F (°F-32) x 0.555 °C pound 0.453 kg
inches 25.4 mm Btu/hr 0.000293 kW/hr
feet 0.305 meters gallons 3.785 liters
CFM 0.028 m³/min psig 27.7 "W.C
SPECIAL DESIGN REQUESTS
Units are sometimes built 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. Units built with special
features are noted with a 5-digit SPO (Special Product Order)
Number on the Serial Plate.
STORAGE PRIOR TO INSTALLATION
If stored outside prior to installation, the unit must be covered.
UNIT LOCATION
DANGER
Appliances must not be installed where they may be exposed
to potentially explosive or ammable atmosphere.
DANGER
Les appareils ne doivent pas être installés à un endroit où ils
risquent d’être exposés à une atmosphère potentiellement
explosive ou inammable.
WARNING
To prevent premature heat exchanger failure, do not locate
ANY gas-red appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the
atmosphere.
AVERTISSEMENT
Pour éviter la panne prématurée de l’échangeur thermique,
ne placez AUCUN appareil à gaz à des endroits où les
vapeurs corrosives (chlorées, halogénées ou acides) sont
présentes dans l’atmosphère
IMPORTANT
1. For installation only in locations not accessible to the
general public.
2. Unit can be operated up to a maximum of 10,000 feet
(3048 m).
IMPORTANT
1. Pour installation uniquement dans des endroits non
accessibles au public.
2. L’unité peut être utilisée jusqu’à un maximum de 3048 m
(10,000 ft).
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 the structural support at the unit location site is
adequate to support the weight of the unit. For proper
operation the unit must be installed in a level horizontal
position.
4. Do not install units in locations where the ue products
can be drawn into the adjacent building openings such as
windows, fresh air intakes, etc.
5. Be sure that the minimum clearances to combustible
materials and recommended service clearances are
maintained. Units are designed for installation on non-
combustible surfaces with the minimum clearances shown
in Figure 7.1 and Table 7.1.
6. Units installed downstream of refrigeration systems, or
exposed to inlet air temperatures of 40°F or less, may
experience condensation, therefore, provisions should
be made for disposal of condensate. Means have been
provided in the bottom pan of the unit to accommodate a
condensate drain line connection ange.
7. When locating units, it is important to consider that the
exhaust vent piping must be connected to the outside
atmosphere.
8. In garages or other sections of aircraft hangars such as
o󰀩ces and shops that communicate with areas used for
servicing or storage, keep the bottom of the unit at least
7' above the oor unless the unit is properly guarded to
provide user protection from moving parts. In parking
garages, the unit must be installed in accordance with the
standard for parking structures ANSI/NFPA 88A, and in
repair garages the standard for repair garages NFPA #88B.
In Canada, installation of heaters in airplane hangars must
be in accordance with the requirements of the enforcing
authority, and in public garages in accordance with the
current CAN/CGA-B149 codes.
9. Do not install units in locations where gas ignition system is
exposed to water spray, rain, or dripping water.

7
5-565.6
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION
Figure 7.1 - Combustible Material and Service
Clearances
2” (5 cm) (D)
3” (7.6 cm) (C)
12”
(30.5 cm)
(A)
Model Size Non-Access
Side (B)
100 thru 175 1" (2.5 cm)
200 thru 960 2" (5 cm)
j3'' (7.6 cm) minimum clearance to combustible material is required from the
vent collar.
Table 7.1 - Recommended Service Clearances
Model Size Access Side
(A)
Non-
Access
Side (B)
Top (C) Bottom
(D)
100-125 20" (50.8cm)
6"
(15.24cm)
10"
(25.4cm) 0
150-175 25" (63.5cm)
200-225 27" (68.58cm)
250-300, 500-600 30" (76.2cm)
350-400, 700-960 41" (104.14cm)
Figure 7.1 - Matériaux combustibles et dégagements
2” (5 cm) (D)
3” (7.6 cm) (C)
12”
(30.5 cm)
(A)
Taille de
modèle
Côté opposé
à la porte (B)
100 à 175 1" (2.5 cm)
200 à 960 2" (5 cm)
jUn dégagement minimal de 7,6 cm (3") jusqu’au matériau combustible est
requis à partir du collet de ventilation.
Tableau 7.1 - Dégagements recommandés pour
l'entretien
Taille de modèle
Côté porte
d'accès
(A)
Côté
opposé
à la
porte
(B)
Dessus
(C) Bas (D)
100-125 20" (50.8cm)
6"
(15.24cm)
10"
(25.4cm) 0
150-175 25" (63.5cm)
200-225 27" (68.58cm)
250-300, 500-600 30" (76.2cm)
350-400, 700-960 41" (104.14cm)
Combustion Air Requirements
Units installed in tightly sealed buildings or conned spaces
must be provided with two permanent openings, one near
the top of the conned space and one near the bottom. Each
opening should have a free area of not less than one square
inch per 1,000 BTU per hour of the total input rating o󰀨 all
units in the enclosure, freely communicating with interior areas
having, in turn adequate inltration from the outside.
For further details on supplying combustion air to a conned
(tightly sealed) space or unconned space, see the National
Fuel Gas Code ANSI Z223.1 of CAN/CGA B149.1 or .2
Installation Code, latest edition.
Sound and Vibration Levels
All standard blower mechanical equipment generates some
sound and vibration that may require attenuation. Libraries,
private o󰀩ces and hospital facilities will require more
attenuation, and in such cases, an acoustical consultant may
be retained to assist in the application. Locating the equipment
away from the critical area is desirable within ducting limitations.
Generally, a unit should be located within 15 feet of a primary
support beam. Smaller deections mean lesser vibration and
noise transmission.

85-565.6
UNIT MOUNTING
UNIT MOUNTING METHODS
Determine the method of mounting that will be used. Be sure
the method of unit support (suspension or oor mounting) is
adequate to support the weight of the unit (see Weights for base
unit and factory installed option weights). For proper operation,
the unit must be installed in a level horizontal position.
Combustible material and service clearances as specied in
Figure 7.1 and Table 7.1 must be strictly maintained. To assure
that ames are directed into the center of the heat exchanger
tubes, the unit must be level in a horizontal position.
Unit Suspension
0.75" (1.9 cm) diameter suspension hanging locations are
provided in the base rail assembly of the unit. Refer to
Figure 46.1 for Suspension Hanging Locations and Figure 8.1
demonstrates how the unit should be suspended and the
suspension rods fastened to the unit base rail. If required,
vibration isolators may be added.
Figure 8.1 - Unit Suspension Method
BLOWER
SECTION
DOOR
ELECTRICAL
SECTION
DOOR
DUCT
FURNACE
0.75" (1.9 cm) SUSPENSION
RODS (BY OTHERS)
(2) 0.75" (1.9 cm) NUTS &
LOCKWASHER
(1) 0.75" (1.9 cm) NUT &
LOCKWASHER
Suspension de l'appareil
Quatre emplacements de suspension de 1,9 cm (0.75") de
diamètre sont fournis dans l’assemblage du rail de base de
l’appareil. Reportez-vous à la Figure 46.1 pour connaître
les emplacements de suspension et la Figure 8.1 démontre
la façon dont l’appareil doit être suspendu et les tiges de
suspension fixées au rail de base de l’appareil. Si nécessaire,
des isolateurs de vibration peuvent être ajoutés.
Figure 8.1 - Méthode de suspension de l’appareil
Porte de la section de la soufflante
Porte de la section électrique
Chaudière canalisée
Tige de suspension de
1,9 cm (0.75") (par des tiers)
(2) Écrou et rondelle de
1,9 cm (0.75")
(1) Écrou et rondelle de
1,9 cm (0.75")
Floor Mounted Units
For oor installations, the oor structure must be adequately
designed to support the live weight load of the unit and any
other required support structure. Additional reinforcement should
be provided, if necessary. The oor should include threaded
5/8-inch anchor bolts spaced according to Figure 8.2, for
securing the unit in place. Anchor bolts should extend at least
1.5" (3.81cm) above the surface of the oor to allow clearance
for mounting washers, nuts and bolts (mounting washers, nuts,
and bolts by others).
Figure 8.2 - Floor Mounted Unit Anchor Bolt
Locations
A
B0.63" (1.59 cm)
diameter (4)
C

9
5-565.6
UNIT MOUNTING
Table 9.1 - Floor Mounted Unit Anchor Bolt
Locations
Digit 2 Model Size Blower Type
(Digit 16) A BC
B
100/125 All 86.37"
(219.38 cm)
36.36"
(92.35 cm)
–
150/175 All 86.37"
(219.38 cm)
40.61
(103.15 cm)
–
200/225 All 86.37"
(219.38 cm)
42.71"
(108.48 cm)
–
250/300 E,F,G, or H 86.37"
(219.38 cm)
45.75"
(116.21 cm)
–
250/300 I,J, or K 112.12"
(284.78 cm)
45.75"
(116.21 cm)
–
350/400 E,F,G or H 86.37"
(219.38 cm)
57.27"
(145.47 cm)
–
350/400 I,J, or K 122.2"
(310.39 cm)
57.27"
(145.47 cm)
–
500/600 G or H 119.52"
(303.58 cm)
45.75"
(116.21 cm)
33.50"
(85.09 cm)
500/600 I,J, or K 155.38"
(394.67 cm)
45.75"
(116.21 cm)
33.50"
(85.09 cm)
700/800 G or H 119.52"
(303.58 cm)
57.27"
(145.47 cm)
33.50"
(85.09 cm)
700/800 I,J,K, or L 155.37"
(394.64 cm)
57.27"
(145.47 cm)
33.50"
(85.09 cm)
840/960 I,J,K, or L 184.61"
(468.91 cm)
57.27"
(145.47 cm)
62.73"
(159.33 cm)
C
100/125 All 115.48"
(293.32 cm)
36.36"
(92.35 cm)
–
150/175 All 115.48"
(293.32 cm)
40.61
(103.15 cm)
–
200/225 All 115.48"
(293.32 cm)
42.71"
(108.48 cm)
–
250/300 E,F,G, or H 115.48"
(293.32 cm)
45.75"
(116.21 cm)
–
250/300 I,J, or K 151.34"
(384.40 cm)
45.75"
(116.21 cm)
–
350/400 E,F,G or H 115.48"
(293.32 cm)
57.27"
(145.47 cm)
–
350/400 I,J, or K 151.34"
(384.40 cm)
57.27"
(145.47 cm)
–
Modèles installés sur le plancher
Pour les installations sur le plancher, la structure du toit doit
être correctement conçue pour soutenir la charge utile de
l'appareil et de toute autre structure de soutien requise. Au
besoin, tout renforcement supplémentaire devra être fourni.
Le plancher doit inclure des boulons d'ancrage letés de 5/8"
espacés comme dans la Figure 9.1 pour xer l'appareil en
place. Les boulons d'ancrage doivent se prolonger au-delà de la
surface du plancher d’au moins 3,81cm (1.5") pour permettre un
dégagement su󰀩sant pour la mise en place des rondelles, des
boulons et des écrous (par des tiers).
Figure 9.1 - Emplacements des boulons d’ancrage
pour appareil installé sur le plancher
A
B(4) diamètre de
1,59 cm (0.63")
C
Tableau 9.1 - Emplacements des boulons d’ancrage
pour appareil installé sur le plancher
2e
chi󰀨re
Taille de
modèle
Type de
ven tilateur
(16e chi󰀨re)
A BC
B
100/125 Tout 86.37"
(219.38 cm)
36.36"
(92.35 cm)
–
150/175 Tout 86.37"
(219.38 cm)
40.61
(103.15 cm)
–
200/225 Tout 86.37"
(219.38 cm)
42.71"
(108.48 cm)
–
250/300 E,F,G, or H 86.37"
(219.38 cm)
45.75"
(116.21 cm)
–
250/300 I,J, or K 112.12"
(284.78 cm)
45.75"
(116.21 cm)
–
350/400 E,F,G or H 86.37"
(219.38 cm)
57.27"
(145.47 cm)
–
350/400 I,J, or K 122.2"
(310.39 cm)
57.27"
(145.47 cm)
–
500/600 G or H 119.52"
(303.58 cm)
45.75"
(116.21 cm)
33.50"
(85.09 cm)
500/600 I,J, or K 155.38"
(394.67 cm)
45.75"
(116.21 cm)
33.50"
(85.09 cm)
700/800 G or H 119.52"
(303.58 cm)
57.27"
(145.47 cm)
33.50"
(85.09 cm)
700/800 I,J,K, or L 155.37"
(394.64 cm)
57.27"
(145.47 cm)
33.50"
(85.09 cm)
840/960 I,J,K, or L 184.61"
(468.91 cm)
57.27"
(145.47 cm)
62.73"
(159.33 cm)
C
100/125 Tout 115.48"
(293.32 cm)
36.36"
(92.35 cm)
–
150/175 Tout 115.48"
(293.32 cm)
40.61
(103.15 cm)
–
200/225 Tout 115.48"
(293.32 cm)
42.71"
(108.48 cm)
–
250/300 E,F,G, or H 115.48"
(293.32 cm)
45.75"
(116.21 cm)
–
250/300 I,J, or K 151.34"
(384.40 cm)
45.75"
(116.21 cm)
–
350/400 E,F,G or H 115.48"
(293.32 cm)
57.27"
(145.47 cm)
–
350/400 I,J, or K 151.34"
(384.40 cm)
57.27"
(145.47 cm)
–

10 5-565.6
UNIT LIFTING
UNIT LIFTING
WARNING
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 qualied
rigging company. Use ALL lifting points. Test lift to ensure
proper balance and rigging.
AVERTISSEMENT
Le non-respect d’une bonne procédure de levage et des
procédures de sécurité qui s’appliquent pourrait mener à
des dommages matériels ou à des blessures graves, voire
mortelles. Le levage doit être e󰀨ectué uniquement par une
entreprise spécialisée dans le gréage. Utilisez TOUS les
points de levage. Testez le levage pour assurer un bon
équilibre et un bon gréage.
Rigging and lifting of the units should only be done by a qualied
rigging company and follow appropriate industry standards,
including but not limited to the appropriate sections of ASME
B30, OSHA 1910, and OSHA 1926.
1. Follow site preparation instructions for overhead
suspension, oor mounting, equipment stand before
installation.
2. Check the Serial Plate(s) of unit with plans to be sure unit
is properly located. Although units may look outwardly
similar, their function, capacities, options, and accessories
will often vary.
3. Check unit dimensions of both the unit base and the
installation location where the unit will be installed.
4. The provisions for lifting are dependant on how the unit
was shipped:
a. All units with standard blower cabinets (Model Digit
16=A through H) are shipped fully crated with skid
supports below the unit. The unit may be lifted from
the bottom by means of a fork lift or other lifting device
only if the shipping support skids are left in place. DO
NOT attempt to lift the unit from the bottom unless the
shipping skid supports are still in place. When lifting
units, make sure the load is balanced.
b. All units with extended blower cabinets (Model Digit
16=I through L) are shipped without a crate and
cannot be lifted with a fork truck. Use a crane or other
overhead lifting device in conjunction with the lifting
holes for safe unit relocation (refer to the Dimensions
for base rail lifting hole locations). See the following
note #5. If the unit must be lifted from the bottom for
nal installation, be sure to properly support the unit
over its entire length to prevent damage.
5. When lifting the equipment with a crane, connect sturdy
steel cables, chains, or straps. For stability in lifting and
lowering and to prevent damage to the unit, include a
spreader bar. Avoid twisting or uneven lifting of the unit.
Test lift the unit to check for proper rigging balance before
hoisting to the desired installation location.
6. Position the unit to its ductwork or where ductwork will be
located and suspend or oor mount the unit. For proper
operation, the unit must be installed in a level horizontal
position. Use a spirit level to ensure that the unit is
suspended or oor mounted correctly.

11
5-565.6
INSTALLATION
Duct Connection to Unit
1. The furnace discharge (units with Model Digit 2=B) is
designed to accept straight ductwork (see Figure 11.1).
The blower section end and bottom openings (all units) and
cooling cabinet section discharge (units with Model Digit
2=C) are designed to accept 90° anged ductwork (see
Figure 11.2).
2. Provide an airtight seal between the ductwork and the unit.
Seams with cracks in the ductwork should be caulked and/
or taped and be of permanent type. All duct connections
MUST be airtight to prevent air leakage.
3. Provide uniform air distribution over the heat exchanger.
Use turning vanes where required to obtain uniform air
distribution. (See Figure 11.1).
4. Provide removable access panels on the downstream side
of the ductwork. (See Figure 11.1.) This opening should
be large enough to view smoke or reect light inside the
casing to indicate leaks in the heat exchanger and to check
for hot spots on heat exchangers due to poor air distribution
or lack of su󰀩cient air (CFM).
Utility Connections
1. Utility and control connections can be made to the unit
from the bottom or through the xed side panels for oor
mounted units. Holes can be made in xed side panels
to accommodate utility connections for any model or as
specied according to the unit dimensional drawings.
Sealing of holes cut in the unit casing for utility connections
should be done with care to prevent air leaks.
2. Refer to the applicable sections to make Venting, Gas
Connections, Electrical Connections, and Cooling Coil
Connections. Make nal unit connections to the electric
power supply and remote control circuits. Caulk all utility
line clearance holes on the unit after connections are
completed.
Figure 11.1 - Recommended Field Installed Discharge
Duct Congurations
*DIMENSION "B" SHOULD NEVER BE
LESS THAN 1/2 OF DIMENSION "A".
AIR
FLOW
SIDE VIEW
AIR
FLOW
PROVIDE LEAK TIGHT ACCESS PANELS
IN SIDE OF DISCHARGE DUCT FOR
HEAT EXCHANGER INSPECTION
PROVIDE LEAK TIGHT ACCESS PANELS
IN SIDE OF DISCHARGE DUCT FOR
HEAT EXCHANGER INSPECTION
TOP VIEW
B*
*DIMENSION "B" SHOULD NEVER BE
LESS THAN 1/2 OF DIMENSION "A".
B*
12" MINIMUM
12" MINIMUM
3" MINIMUM
TURNING VANES
3" MAXIMUM
3" MINIMUM
TURNING VANES
3" MAXIMUM
A
A
Figure 11.2 - Blower Section and Cooling Cabinet
Duct Connections
1/2” BLOWER AND/OR
COOLING COIL
CABINET
D
U
C
TWOR
K

12 5-565.6
INSTALLATION
VENTING
WARNING
1. Gas red heating equipment must be vented - do not
operate unvented.
2. Units have a built-in power exhauster - additional external
power exhausters are not required or permitted.
3. If you are replacing an existing heater, it may be necessary
to resize the venting systems. Improperly sized venting
systems can result in vent gas leakage or the formation of
condensate. Refer to the National Fuel Gas Code ANSI
Z223.1 or CSA B149.1 latest edition. Failure to follow these
instructions can result in injury or death.
4. Under no circumstances should two sections of double
wall vent pipe be joined together within one horizontal vent
system due to the inability to verify complete seal of inner
pipes.
AVERTISSEMENT
1. Les équipements de chau󰀨age au gaz doivent avoir un
système de ventilation – ne les faites pas fonctionner sans
évacuation des gaz.
2. Les unités sont munies d’un extracteur électrique intégré
– des extracteurs électriques externes supplémentaires ne
sont pas requis ni permis.
3. Si vous remplacez un appareil de chau󰀨age existant, vous
aurez peut-être à modier les systèmes de ventilation. Des
systèmes de ventilation de diamètre insu󰀩sant peuvent
causer des fuites de gaz ou la formation de condensat.
Reportez-vous au code National Fuel Gas ANSI Z223.1 ou
à la dernière édition de la norme CSA B149.1. Le non-
respect de ces directives pourrait entraîner des blessures
graves, voire mortelles.
4. Il est interdit d’accoupler deux longueurs de tuyau à double
paroi dans une même installation d’évacuation horizontale
étant donné l’impossibilité de vérier l’étanchéité des
raccords du tuyau intérieur.
General Venting Instructions
1. Installation of venting must conform with local building
codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition.
In Canada, installation must be in accordance with CAN/
CGA-B149.1 for natural gas units and CAN/CGA-B149.2
for propane units.
2. To determine the Venting Category of the unit being
installed, refer to Table 12.1
Table 12.1 - Venting Category Determination
Venting Category Vent Conguration
I jVertically vented units only.
III kHorizontally vented units only.
jVent is negative pressure, non-condensing. Follow standard venting
requirements.
kVent is positive pressure, non-condensing. Vent must be gastight.
3. For units vented as Category I, refer to Table 12.2 for
vent sizing. Vent sizing for units vented as Category III are
covered in a later section on page 14. Do not use a vent
pipe smaller than the size of the outlet or vent transition
of the appliance. The pipe should be suitable corrosion
resistant material. Follow the National Fuel Gas Code for
minimum thickness and composition of vent material. The
minimum thickness for connectors varies depending on the
pipe diameter.
Table 12.2 - Category I Minimum Vent Pipe Sizing
Model Size Minimum Vent Pipe Diameter k
100-125 4"
150-175 5" j
200-960 6"
jRequires a 4" to 5" adapter for the larger 5" vent pipe diameter.
kPer furnace.
4. For Category I vent systems limit length of horizontal
runs to 75% of vertical height. Install with a minimum
upward slope from unit of 1/4 inch per foot and suspend
securely from overhead structure at points no greater than
3 feet apart. For best venting, put vertical vent as close
to the unit as possible. A minimum of 12" straight pipe is
recommended from the power exhauster outlet before
turns in the vent system. Fasten individual lengths of vent
together with at least three corrosion-resistant sheet-metal
screws.
5. It is recommended that vent pipes be tted with a tee with
a drip leg and a clean out cap to prevent any moisture in
the vent pipe from entering the unit. The drip leg should be
inspected and cleaned out periodically during the heating
season.
6. The National Fuel Gas Code requires a minimum clearance
of 6 inches from combustible materials for single wall vent
pipe. The minimum distance from combustible materials is
based on the combustible material surface not exceeding
160°F. Clearance from the vent pipe (or the top of the unit)
may be required to be greater than 6 inches if heat damage
other than re (such as material distortion or discoloration)
could result.
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 tting at
the low point of the vent system and provide a drip leg with
a clean out cap as shown in Figure 13.1.
8. When the vent passes through a combustible wall or oor,
a metal thimble 4 inches greater than the vent diameter
is necessary. If there is 6 feet or more of vent pipe in the
open space between the appliance and where the vent
pipe passes through the wall or oor, the thimble need only
be 2 inches greater than the diameter of the vent pipe. If
a thimble is not used, all combustible material must be cut
away to provide 6 inches of clearance. Any material used to
close the opening must be noncombustible.
9. Do NOT use dampers or other devices in the vent pipes.
10. Precautions must be taken to prevent degradation of
building materials by ue products.
11. For category I vent systems the outlet of the vent should
extend as shown in Figure 13.1 and Table 13.1 and
Table 13.2.

13
5-565.6
INSTALLATION
12. Use a listed vent terminal to reduce downdrafts and
moisture in vent.
13. For instructions on common venting refer to the National
Fuel Gas Code.
14. The vent must terminate no less than 5' above the vent
connector for Category I vent systems.
15. A unit located within an unoccupied attic or concealed
space shall not be vented with single wall vent pipe.
16. Single wall vent pipe must not pass through any attic,
inside wall, concealed space, or oor.
17. Do NOT vent units into a masonry chimney.
18. When condensation may be a problem, the venting system
shall not terminate over public walkways or over an area
where condensation or vapor could create a nuisance or
hazard or could be detrimental to the operation of regulator
relief openings or other equipment.
19. In cold ambient conditions, such as Canada, the following
items are recommended for proper operation and
equipment life:
• The vent pipe must not pass through an unheated
space or interior part of an open chimney unless the
vent pipe is insulated.
• Where the vent pipe may be exposed to extreme cold,
or come into contact with snow or ice, the entire vent
must be insulated or double wall (includes outdoors). It
is preferred that the double wall vent is one continuous
piece but a joint is allowed outside the building.
• The heater system shall be checked at least once a
year by a qualied service technician.
Figure 13.1 - Vertical Category I Vent System
* SIZE ACCORNING
TO EXPECTED
SNOW DEPTH.
DISTANCE "D" TO
WALL OR ADJOINING
BUILDING
10 FEET OR LESS
TO ROOF PEAK
ROOF PITCH IS:
X / 12
TEE WITH DRIP LEG
AND CLEANOUT CAP
(SLOPE PIPE UP
1/4" PER FOOT
TOWARD DRIP LEG)
ROOF
FLASHING
USE LISTED
THIMBLE
THROUGH
CEILING
LISTED
TERMINAL
TEE WITH DRIP LEG
AND CLEANOUT CAP
(SLOPE PIPE UP
1/4" PER FOOT
TOWARD DRIP LEG)
USE LISTED
THIMBLE
THROUGH
CEILING
USE LISTED
THIMBLE
THROUGH
ROOF
ROOF
FLASHING
LISTED
TERMINAL
12" MINIMUM
3 FEET
MINIMUM*
12" MINIMUM
"H" FEET MINIMUM
PER TABLE 13.1
2 FEET MINIMUM
X
12"
MAINTAIN MINIMUM
CLEARANCE TO
COMBUSTIBLES
"H" FEET MINMUM
ABOVE WALL OR
ADJOINING
BUILDING PER
TABLE 13.2
MAINTAIN MINIMUM
CLEARANCE TO
COMBUSTIBLES
Table 13.1 - Minimum Height from Roof to Lowest
Discharge Opening
Roof Rise
“X” (in)
Equivalent
Roof Pitch
Minimum Height
“H” (ft) j
0-10 Flat to 10/12 3.00
10-12 10/12 to 12/12 4.00
12-14 12/12 to 14/12 5.00
14-16 14/12 to 16/12 6.00
16-18 16/12 to 18/12 7.00
18-21 18/12 to 21/12 8.00
jIncrease "H" as required to accommodate snow depth
Table 13.2 - Minimum Height Above Adjacent Wall
Less than 10 Feet Away
"D" "H"
10 Feet or Less 2 Feet Minimum
Greater than 10 Feet No Additional Height Required

14 5-565.6
INSTALLATION
Additional Requirements for Horizontally Vented
Category III Units
1. Seal all seams and joints of ungasketed single wall pipe
with a metallic tape or silastic suitable for temperatures
up to 350°F. (3M aluminum foil tapes 433 or 363 are
acceptable.) Wrap tape two full turns around the vent pipe.
2. Refer to Table 14.1 for total minimum and maximum vent
lengths making the vent system as straight as possible.
The equivalent length of a 90° elbow is 5 feet for 4"
diameter and 7 feet for 6" diameter.
Table 14.1 - Horizontal Category III Vent Sizing
Requirements j
Model
Size
Vent Connector
Diameter k
Minimum Vent
Pipe Diameter
Maximum Vent
Length
100-175 4" 4" 55'
200 6" 5" j70'
225 6" 6" 70'
250-300, 500-600 6" 6" 63'
350-400, 700-960 6" 6" 70'
jUnit can be vented with 5" diameter pipe if a 6" to 5" reducer is used. Otherwise, use 6" pipe.
kPer furnace.
3. The vent terminal must be Modine part number:
• 5H072285-0001 (Item Code 27866) for 4" vent pipe
• 5H072285-0004 (Item Code 27867) for 5" vent pipe
• 5H072285-0002 (Item Code 27868) for 6" vent pipe
4. The vent must extend a minimum of 12" beyond the
exterior wall surface and must be supported as shown
in Figure 14.1. Precautions must be taken to prevent
degradation of building materials by ue products.
5. The vent system shall terminate at least 3 feet above any
forced air inlet (except direct vent units) located within 10
feet, and at least 4 feet below, 4 feet horizontally from,
or 1 foot above any door, window, or gravity air inlet into
any building. The bottom of the vent terminal shall be
located above the snow line or at least 1 foot above grade;
whichever is greater. When located adjacent to public
walkways the vent system shall terminate not less than 7
feet above grade.
6. The venting system must be exclusive to a single unit, and
no other unit is allowed to be vented into it.
7. Horizontally vented units must use single wall vent pipe
although one continuous section of double wall vent pipe
may be used with the vent system. Under no circumstances
should two sections of double wall vent pipe be joined
together within one vent system due to the inability to verify
complete seal of inner pipes.
8. Category III vent systems listed by a nationally recognized
agency and matching the diameters specied may be used.
Di󰀨erent brands of vent materials may not be intermixed.
Figure 14.1 - Horizontal Venting
(SLOPE PIPE DOWN
1/4" PER FOOT
TOWARD DRIP LEG)
SPECIFIED
TERMINAL
TEE WITH DRIP LEG
AND CLEANOUT CAP
USE LISTED THIMBLE
THROUGH WALL
UNIT
STEEL ANGLE
VENT TERMINATION
SUPPORT BRACKET
(WHERE REQUIRED)
12" MIN
9" MIN
9" MIN
GAS CONNECTIONS
WARNING
1. All eld gas piping must be pressure/leak tested prior to
operation. Never use an open ame. Use a soap solution
or equivalent for testing.
2. Gas pressure to appliance controls must never exceed 3.4
kPa (14" W.C. or 1/2 psi).
3. To reduce the opportunity for condensation, the minimum
sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
AVERTISSEMENT
1. Toutes les canalisations de gaz sur site doivent être
testées (pression/fuites) avant usage. Ne recherchez
jamais les fuites avec une amme nue. Utilisez plutôt de
l’eau savonneuse ou un produit équivalent.
2. La pression de gaz aux commandes de l’appareil ne doit
jamais dépasser 3.4 kPa (35,5 cm C.E. ou 1/2 psi).
3. Pour réduire le risque de condensation, l’entrée minimum
dans l’appareil au niveau de la mer, telle qu’indiquée sur la
plaque de série, ne doit pas être moins de 5 % inférieure à
la valeur d’entrée nominale des appareils à double valeur
nominale.
CAUTION
Purging of air from gas supply line should be performed as
described in ANSI Z223.1 - latest edition “National Fuel Gas
Code”, or in Canada in CAN/CGA-B149 codes.
ATTENTION
La purge de l’air des tuyauteries de gaz doit se faire selon la
procédure ANSI Z223.1 de la dernière édition du « National
Fuel Gas Code » ou des codes CAN/CGA-B149 du Canada.
IMPORTANT
To prevent premature heat exchanger failure, the input to the
appliance, as indicated on the serial plate, must not exceed
the rated input by more than 5%.
IMPORTANT
Pour éviter une défaillance prématurée de l’échangeur de
chaleur, le pouvoir calorique du gaz utilisé ne doit pas
excéder de plus de 5 % la valeur nominale inscrite sur la
plaque signalétique de l’appareil.
(continued next page)

15
5-565.6
INSTALLATION
1. Installation of piping must conform with local building
codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1 (NFPA 54) - Latest Edition.
In Canada, installation must be in accordance with CAN/
CGA-B149.1 for natural gas units and CAN/CGA-B149.2
for propane units.
2. Piping to units should conform with local and national
requirements for type and volume of gas handled, and
pressure drop allowed in the line.
3. Refer to Model Digits 4-6 of the Model Nomenclature
on page 58 and the value on the unit Model ID plate
(not individual furnace serial plates) to determine the gas
heating capacity in Thousands of Btu/hr (MBH). The
Model ID plate is located on the blower section electrical
compartment door. See Figure 15.1 for an example Model
ID plate.
Figure 15.1 - Model ID Plate Example
4. Refer to Table 16.3 to determine the cubic feet per hour
(cfh) for the type of gas and size of unit to be installed.
Using this cfh value and the length of pipe necessary,
determine the pipe diameter from Table 16.1 for Digit
11=N or Table 16.2 for Digit 11=P. Where several units are
served by the same main, the total capacity, cfh and length
of main must be considered. While the gas connection(s)
on the unit may be smaller than the required supply pipe
diameter, do not use pipe sizes smaller than what is
required leading up to the unit. At the unit, reduce the pipe
size down to the appropriate size (sizes 75-200 are 1/2"
connections, 225-960 are 3/4" connections). Avoid pipe
sizes smaller than 1/2". The inlet pressure to the unit must
be 6-7" W.C. for natural gas and 11-14" W.C. for propane
gas. When sizing the inlet gas pipe diameter, be sure the
unit supply pressure can be met after the line pressure drop
has been subtracted. If the line pressure drop is too high,
refer to NFPA 54 National Fuel Gas Code for other gas pipe
capacities.
5. 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 seat and a manual shut-o󰀨 valve external of the
unit casing, and adjacent to the unit for emergency shut-
o󰀨 and easy servicing of controls, including a 1/8" NPT
plugged tapping accessible for test gauge connection (See
Figure 15.2). Verify the manual shut-o󰀨 valve is gas tight
on an annual basis.
6. Provide a sediment trap before each unit in the line where
low spots cannot be avoided. (See Figure 15.2).
Figure 15.2 - Recommended Sediment Trap/Manual
Shut-o󰀨 Valve Installation - Side or Bottom Gas
Connection
GAS
SUPPLY LINE
GAS
SUPPLY LINE
GROUND
JOINT
UNION
W/ BRASS
SEAT
MANUAL GAS
SHUT-OFF VALVE
3"
MIN.
SEDIMENT
TRAP
PLUGGED
1/8" NPT TEST
GAGE CONNECTION
TO
CONTROLS
jManual shut-off valve is in the “OFF” position when handle is perpendicular to
pipe.
7. When Pressure/Leak testing, pressures above 14" W.C.
(1/2 psi), close the eld installed shut-o󰀨 valve, disconnect
the appliance and its combination gas control from the gas
supply line, and plug the supply line before testing. When
testing pressures 14" W.C. (1/2 psi) or below, close the
manual shut-o󰀨 valve on the appliance before testing.

16 5-565.6
INSTALLATION
Table 16.1 - Gas Pipe Capacities - Natural Gas j
Pipe
Length (ft)
Capacity in MBH by Nominal Pipe Diameter
1∕2” 3∕4” 1” 1 1∕4” 1 1∕2” 2” 2 1∕2” 3”
10 138 287 540 1,113 1,659 3,203 5,103 9,009
20 95 197 371 762 1,145 2,195 3,507 6,195
30 76 159 298 612 917 1,764 2,814 4,977
40 65 135 255 524 784 1,512 2,405 4,253
50 58 120 226 464 695 1,344 2,132 3,770
60 53 109 205 420 630 1,218 1,932 3,423
70 48 100 188 386 580 1,113 1,775 3,150
80 44 93 175 360 540 1,038 1,659 2,930
90 42 87 165 338 506 974 1,554 2,741
100 40 83 155 319 478 921 1,470 2,594
125 35 74 138 282 423 816 1,302 2,300
150 32 66 125 256 384 739 1,176 2,079
175 29 61 114 235 353 680 1,082 1,911
200 27 57 107 219 329 632 1,008 1,785
250 24 50 95 194 291 561 894 1,575
Gas pipe capacities based on Table 6.2.1(a) of NFPA 54 for schedule 40
metallic pipe with inlet pressure less than 2 psi, with a pressure drop of 0.3" w.c.
and gas specific gravity of 0.60.
Table 16.2 - Gas Pipe Capacities - Propane Gas k
Pipe
Length (ft)
Capacity in MBH by Nominal Pipe Diameter
1∕2” 3∕4” 1” 1 1∕4” 1 1∕2” 2” 2 1∕2” 3”
10 291 608 1,150 2,350 3,520 6,790 10,800 19,100
20 200 418 787 1,620 2,420 4,660 7,430 13,100
30 160 336 632 1,300 1,940 3,750 5,970 10,600
40 137 287 541 1,110 1,660 3,210 5,110 9,030
50 122 255 480 985 1,480 2,840 4,530 8,000
60 110 231 434 892 1,340 2,570 4,100 7,250
80 101 212 400 821 1,230 2,370 3,770 6,670
100 94 197 372 763 1,140 2,200 3,510 6,210
125 89 185 349 716 1,070 2,070 3,290 5,820
150 84 175 330 677 1,010 1,950 3,110 5,500
175 74 155 292 600 899 1,730 2,760 4,880
200 67 140 265 543 814 1,570 2,500 4,420
250 62 129 243 500 749 1,440 2,300 4,060
kGas pipe capacities based on Table 6.3.1(d) of NFPA 54 for schedule 40
metallic pipe with inlet pressure of 11.0" w.c., with a pressure drop of 0.5" w.c.
and gas specific gravity of 1.50.
Table 16.3 - Burner Orice Sizing and Gas
Consumption
Model
Size
Gas Type Orice
Qty
Natural jPropane k
100 Cfh 96.1 40.0 2
Orice Drill Size 30 45
125 Cfh 120.2 50.0 2
Orice Drill Size 25 42
150 Cfh 144.2 60.0 3
Orice Drill Size 30 45
175 Cfh 168.3 70.0 3
Orice Drill Size 27 43
200 Cfh 192.3 80.0 3
Orice Drill Size 23 42
225 Cfh 216.3 90.0 3
Orice Drill Size 20 39
250 Cfh 240.4 100.0 4
Orice Drill Size 25 42
300 Cfh 288.7 120.0 4
Orice Drill Size 20 39
350 Cfh 336.5 140.0 6
Orice Drill Size 27 43
400 Cfh 384.6 160.0 6
Orice Drill Size 23 42
500
l
Cfh 240.4 100.0 4
Orice Drill Size 25 42
600
l
Cfh 288.7 120.0 4
Orice Drill Size 20 39
700
l
Cfh 336.5 140.0 6
Orice Drill Size 27 43
800
m
Cfh 384.6 160.0 6
Orice Drill Size 23 42
840
l
Cfh 336.5 140.0 6
Orice Drill Size 27 43
960
m
Cfh 384.6 160.0 6
Orice Drill Size 23 42
j Based on natural gas properties of 1,050 Btu/ft3 and specific gravity of 0.60.
k Based on propane gas properties of 2,500 Btu/ft3 and specific gravity of 1.53.
lModel sizes 500-800 contain 2 furnaces. Values shown are per furnace.
mModel sizes 840-960 contain 3 furnaces. Values shown are per furnace

17
5-565.6
INSTALLATION
Considerations for Elevation
The standard ratings for Models DBG/DCG and DBP/DCP
are certied 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. The exception is for units in Canada, CSA requires that
ratings be reduced 10% for elevations between 2,001 and 4500
feet. The following instructions are for units that will be installed
over 2,000 feet elevation. If this does not apply, you may skip
ahead to the Electrical Connections section on page 18. Unit
can be operated up to a maximum of 10,000 feet (3048 m).
MANIFOLD PRESSURE ADJUSTMENT
The unit manifold pressure is factory set for operation at
elevations up to 2,000 feet as follows:
• For Natural Gas units, 3.5" W.C. based on a gas heating value
of 1,050 BTU/ft3.
• For Propane Gas units, 10.0" W.C. based on a gas heating
value of 2,500 BTU/ft3.
For higher elevations, some utility companies may derate the
BTU content (heating value) of the gas provided at altitude to
a lower value to allow certain heating appliances to be used
with no manifold pressure adjustments. For this reason it is
necessary that the supplying utility be contacted for detailed
information about the gas type and BTU content (heating value)
before operating any heater. Table 17.1 shows the standard
derated heating values of natural and propane gases at various
elevations.
Table 17.1 -
Gas Heating Values at Altitude (Btu/ft3) jkln
Altitude (ft) Natural Gas Propane
0-2,000 1,050 2,500
2,001-3,000 929 l2,212 m
3,001-4,000 892 l2,123 m
4,001-4,500 874 l2,080 m
4,501-5,000 856 2,038
5,001-6,000 822 1,957
6,001-7,000 789 1,879
7,001-8,000 757 1,803
8,001-9,000 727 1,731
9,001-10,000 698 1,662
jValues shown are for 3.5" W.C. manifold pressure for Natural Gas and 10.0"
W.C. for Propane Gas. If the local utility supplies gas with a different Btu/ft3
value, use Equation 17.1 to calculate the required manifold pressure.
kGas heating values shown are derated 4% per 1,000' of elevation (10%
between 2,000' and 4,500' elevation in Canada) in accordance with ANSI
Z223.1 and CSA-B149, respectively.
l 945 Btu/ft3 for Canada
m 2,250 Btu/ft3 for Canada
nWhen installed at altitudes above 2,000', a pressure switch may need to be
changed. Refer to Table 17.2 and Table 17.3 to determine if a switch change
is required.
If the utility is supplying gas with heating values SAME as
shown in Table 17.1, the manifold pressure should remain set
to 3.5" W.C. for natural gas and 10.0" W.C. for propane gas and
you may proceed to the section on this page titled "Selection of
the Proper High Altitude Kit".
If the utility is supplying gas with heating values DIFFERENT
than shown in Table 17.1, use Equation 17.1 to determine the
appropriate manifold pressure for the elevation and gas heating
value being supplied. Note what that value is, as it will be
needed later for Start-Up.
Proceed to the section on this page titled "Selection of the
Proper High Altitude Kit".
Equation 17.1 - Manifold Pressure for Gas Heating
Values Di󰀨erent Than Shown in Table 17.1
Where:
MPELEV = Manifold Pressure (" W.C.) at installed
elevation
BTUTBL = BTU/ft3 content of gas from Table 17.1
BTUACT = BTU/ft3 content of gas obtained from
the utility company
MPSL = Manifold Pressure (" W.C.), at Sea
Level (use 3.5" W.C. for natural gas
and 10.0" W.C. for propane)
Note:For units equipped with two-stage or modulating gas
controls, only the high re manifold pressure needs to
be adjusted. No adjustments to the low re manifold
pressure are necessary on these units.
Selection of the Proper High Altitude Kit
All units installed at elevations greater than 2000 feet above
sea level require a kit, in addition to potential manifold pressure
adjustment outlined in the previous step. To determine the
proper kit to use, refer to Table 17.2.
Table 17.3 shows the contents of the kit. For more information,
refer to the latest revision of Modine Bulletin 75-530.
Table 17.2 - High Altitude Kit Selection Table jkl
Model Size
(Digits 4-6)
Elevation Above Sea Level (ft)
2,001-5,500 5,501-6,500 6,501-7,500
100-350
500-700
840
Item
Code 67248 67248 67248
400
800
960
Item
Code 67248 68409 68411
jApplies to both installations in the U.S. and Canada.
kApplies to both natural and propane gas.
lSizes 75-400 require a kit qty. of 1, sizes 500-800 require a kit qty of 2,
sizes 840-960 require a kit qty of 3.
Table 17.3 - High Altitude Kit Contents
Item
Code
Kit Contents
High Altitude
Conversion Label
Pressure
Switch
Installation
Instructions
67248 Yes No Yes
68409 Yes Yes Yes
68411 Yes Yes Yes
If a unit is to be installed at higher elevations and converted
from natural gas to propane gas operation, a propane
conversion kit must be used in conjunction with the manifold
pressure adjustment and high altitude kit listed above. For the
Selection and Installation Instructions for propane conversion
kits, please see the latest revision of Literature #75-511.

18 5-565.6
INSTALLATION
ELECTRICAL CONNECTIONS
WARNING
1. Disconnect power supply before making wiring connections
or working on this equipment. Follow all applicable safety
procedures to prevent accidental power up. Failure to
do so can result in injury or death from electrical shock or
moving parts and may cause equipment damage.
2. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
di󰀨erent from the wiring diagram could result in a hazard to
persons and property.
3. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than rated
voltage.
4. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
AVERTISSEMENT
1. Débranchez l’alimentation électrique avant d’e󰀨ectuer
des connexions ou de travailler sur l’appareil. Respectez
toutes les procédures de sécurité qui s’appliquent pour
éviter toute mise en marche accidentelle. Le non-respect
de cette directive peut entraîner des blessures ou la mort
causées par un choc électrique ou des pièces mobiles, en
plus d’endommager l’appareil.
2. Tous les appareils doivent être branchés de manière
strictement conforme au diagramme fourni. Tout câblage
di󰀨érent de celui du schéma peut créer des risques de
dommages matériels ou de blessures.
3. Assurez-vous que la tension d’alimentation de l’appareil,
comme indiqué sur la plaque de série, n’est pas de 5 %
supérieure à la tension nominale.
4. Tout câblage usine d’origine exigeant un remplacement
doit être remplacé par un câble d’indice thermique nominal
de 105 °C.
CAUTION
1. Do not reuse any mechanical or electrical component
which has been wet. Such component must be replaced.
2. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% less than the rated
voltage.
ATTENTION
1. Ne tentez pas de réutiliser un composant mécanique ou
électrique qui a été mouillé. Ces composants doivent être
remplacés.
2. Vériez que la tension d’alimentation de l’appareil n’est pas
inférieure de plus de 5 % à la tension nominale inscrite sur
la plaque de série.
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 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 job specic wiring diagram are provided
with each unit, one located in the duct furnace electrical
junction box and one in the electrical section of the unit.
Refer to this diagram for all wiring connections.
3. External electrical connections to be installed include:
• Supply power (120, 208, 240, 480, or 600 volts).
• Thermostats, remote monitoring panels, building
pressure sensors, time clocks, or any other accessory
control devices that may be supplied (24 volts).
4. All supply power electrical connections are made in the
electrical section of the unit. The low voltage (thermostat
and accessory control devices) can be wired to either the
electrical section or the duct furnace electrical junction box.
Refer to the wiring diagram for the terminal location of all
low voltage wiring.
5. Refer to the unit dimensional drawings in this document
for the location of the drill locator dimples in the side and
bottom of the unit for eld drilling the hole for the electrical
conduit entry.
6. Control wiring consists of both 24V analog control wiring
and for models with Model Digit 12=9, low current digital
control signal wiring. To avoid signal interference, the two
types should be run in conduit separate from power wiring.
The analog control wiring should be shielded at one end
of the wiring run. Wiring should be stranded, twisted, and
shielded communication wire.
7. The wire gauge must be sized according to the National
Electric Code or CSA code based on the power supply
voltage, amp draw, and length of run. Refer to Table 18.1
for maximum wire lengths that can be wired between
components and the terminal block on the unit based on
the wire gauge being used.
Table 18.1 - 24V and Digital Control Wire Lengths
Minimum
Recommended
Wire Gauge
Maximum Distance (feet) from
Control Device to Unit
24V Control Wiring Digital Control Wiring
22 n/a 120
20 n/a 200
18 75 300
16 125 500
14 175 n/a

19
5-565.6
INSTALLATION
8. FOR UNITS WITH MODEL DIGIT 12=9 (MODINE
CONTROL SYSTEM OPTION): Some eld wiring to the
factory terminal strip may include terminal strip connections
that are designed to clamp down on the wires. To properly
connect the wires to the terminal strip:
• Push a small at-head screwdriver into the square hole
on the terminal. Press rmly until the screwdriver hits
the back stop and opens the terminal (see Figure 19.1).
• Remove approximately 3/8” of insulation from the end of
the wire and push the stripped wire into the oval hole in
the terminal.
• Remove the screwdriver. Pull on the wire to make sure
that it is securely clamped in the terminal.
• Make sure that the terminal clamp is in contact with bare
wire (insulation removed).
Figure 19.1 - Terminal Strip Wiring (Model Digit 12=9)
Test Probe
Points
Terminal Num-
bers
Oval Holes
for Wiring
(two rows each)
Square Holes
for Wire Release
(two rows each)
9. Depending on the conguration of the unit controls,
there may be sensors that are eld installed. Review the
unit ordered to verify that the sensors supplied match
the conguration of the unit. The following are sensors
that may be included for eld installation (for installation
instructions, refer to the instructions included with the
individual sensors):
• Supply Air Temperature Sensor
This sensor is required on all units and is mounted
in the supply air ductwork downstream of the unit
discharge.
• Outdoor Air Sensor
This sensor is required on all units except 100% return
air units. The sensor is duct mounted in the inlet
ductwork.
• Return Air Sensor
This sensor is required on all units that have a mixture
of outside and return air. The sensor is mounted in the
return air ductwork.
• Space Temperature/Humidity Sensor
This sensor is required on all units that have space
temperature/humidity reset control.
• Duct Pressure Sensor
This sensor is required on all units that have duct
pressure control through variable frequency drive
control on the supply air blower.
• Space CO2 Sensor
This sensor is required on all units that have demand
based ventilation control based on space CO2
concentration.
• Duct Mounted Smoke Detector
This sensor is mounted in the supply air or return air
ductwork.
For further instructions on the above sensor(s), refer
to the installation instructions that shipped with the
sensor(s).
10. Make sure all multi-voltage components (motors,
transformers, etc.) are wired in accordance with the power
supply voltage.
11. The power supply to the unit must be protected with
a fused or circuit breaker disconnect switch. Refer to
the Component Locations (Figure 28.1) for the factory
mounted disconnect switch location and then review the
unit to determine if a factory installed dead front disconnect
switch was provided. Accessory eld installed disconnect
switches should be mounted where required by the
National Electric Code as shown in Figure 19.2. For fusible
disconnect switches, refer to the Model Identication plate
to determine the fuse size.
12. The power supply must be within 5% percent of the voltage
rating and each phase must be balanced within 2 percent
of each other. If not, advise the utility company.
Figure 19.2 - Recommended Field Installed
Disconnect Switch Mounting Locations
BLOWER
SECTION
DOOR
ELECTRICAL
SECTION
DOOR
DUCT
FURNACE
ELECTRIC SUPPLY
COMPONENTS MUST BE
CLEAR OF SERVICE DOORS
DISCONNECT
SWITCH WIRING,
AND CONNECTOR

20 5-565.6
INSTALLATION
Models with Optional Cooling Coils
Models with a cooling section can be provided with a factory
installed direct expansion (DX) evaporator, or the coil can be
eld supplied and installed by others. For units equipped with a
factory installed cooling coil (Digit 23 = 1), refer to the packing
slip to determine the coil type provided.
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. The cabinet includes two doors, a removable upper door
for service access to the coil once the plumbing has been
installed and a lower door which includes a factory supplied 1"
stubbed drain connection to the exterior of the cabinet. Field
connections for coil inlet and outlet piping can be made through
the cabinet corner post or back of the unit. The cooling section
duct transition includes 1.5" (3.8 cm) anges for fastening the
sides of the coil. The bottom duct transition is angled to remove
any condensation that may be entrained in the supply air
stream.
For eld supplied coils, do not exceed the maximum coil
dimensions listed in Literature 82-135. The dimensions listed
are for the maximum coil dimensions. If the coil supplied is
smaller than the listed dimensions, eld supplied blank o󰀨 plates
are required to prevent air bypass around the coil. The coil is
supported by two 14 gauge support rails which contain mounting
provisions for fastening 4" (10.2 cm), 5" (12.7 cm), 6" (15.2 cm),
7.5" (19.1 cm), 10" (25.4 cm) deep coils.
Figure 20.1 - Cooling Section
Optional double
wall construction DX single circuit (shown) and dual
circuit coils available
Optional Factory
Installed DX
Fin spacings of
10,12 or 14 fins
per inch
Adjustable mounting
bracket for 4 and 6
row coils
Full coverage
3-way sloping
409 stainless
steel drain pan
1" (2.5 cm) stubbed drain
connection
Right or left hand coil header
access to match gas controls
Condensate Drain Pan Trap
The condensate drain line needs to include a eld supplied
P-trap immediately downstream of the connection to the unit.
This trap should extend at least 2" (5 cm) below the connection
to prevent air pressure from forcing air into the unit. The
trap should be primed with a water/glycol solution to prevent
freezing.
Direct Expansion (DX) Piping
The refrigerant lines should be insulated to prevent warming
or cooling of the refrigerant. If the suction line is allowed to be
cooled, liquid will condense in the line and can severely damage
the compressor. If the liquid line is warmed, the refrigerant
can "ash" into a gas. This will cause erratic operation of
the expansion device and impair the heat transfer ability of
the cooling coil. Long runs of piping need to be periodically
supported to prevent excess vibration that can damage the
piping and joints. It is recommended to provide dampening
supports at intervals of length equivalent to 15 tube diameters.
Figure 20.2 - General DX Piping
SUCTION LINE
EXPANSION
VALVE
(BY OTHERS)
REMOTE
SENSING BULB
STRAPS SUCTION CONNECTION
COIL
SUCTION HEADER
DISTRIBUTOR
EQUALIZER LINE
NOZZLE
LIQUID LINE
1. Inspect the refrigerant distributor and verify that the nozzle
is in place.
2. All eld brazing and welding should be performed using
high quality materials and an inert gas purge (such as
nitrogen) to reduce oxidation of the internal surface of the
coil.
3. For DX coils, the use of lter-dryers in the system piping is
recommended along with a sight glass that has a moisture
indicator.
4. Connect the suction line and suction connection.
5. Install the expansion valve (By Others). Follow the
expansion valve manufacturer's recommendations for
installation to avoid damaging the valve.
6. Connect the liquid line to the expansion valve. Pressurize
the coil, expansion valve assembly and suction connection
to 100 psig with dry nitrogen or other suitable gas. The coil
hould be left pressurized for a minimum of 10 minutes.
7. If the coil holds pressure, the installation can be considered
leak free. If the pressure drops by 5 psi or less,
repressurize the coil and wait another 10 minutes. If the
pressure drops again, there are more than likely one or
more small leaks, which should be located and repaired.
Pressure losses greater than 5 psi would indicate a larger
leak, which should be isolated and repaired. Be sure to
check valves and ttings as potential sites for leakage or
bleed.