Modine Manufacturing 6-582 User manual

October, 2003
INSTRUCTIONS
Time Delay Relay Board Replacement
model HD
6-582
55HH7788667777AA
Perform the following to the unit.
1. Shut off the gas supply and electrical power to the unit.
2. Remove the Blue wires (approximately 6" long Blue wire
with a ¼" Female wire connector at each end) from the "H"
of terminals of the Time Delay Relay. Also remove the
other ends of the blue wires attached to the to Terminal
Board. One wire is attached to the Com terminal and the
other is attached to the "H" terminal. Discard of both blue
wires.
3. Remove and RETAIN the Black wiring assembly
(approximately 6" long Black wire with a ¼" Female wire
connector at each end) that connects the "3" terminal from
the time delay relay to "L1" of the transformer.
4. Remove the remaining wires from the terminal board (do
not disconnect other end of wires). Remove and discard
the 3 (three) terminal adapters (see fig 1.1).
5. Remove the sheet metal screws from the old terminal
board. Retain 2 (two) of the screws and discard of the
remaining screws as well as the old terminal board.
6. Remove the remaining wire from the time delay relay.
Remove the sheet metal screws from the time delay relay.
Discard the screws and time delay relay.
Figure 1.1
Terminal Adapter
7. Discard all paper copies of the wiring diagram 5H75034-2
supplied with the unit and replace it with wiring diagram
5H78166 supplied with kit.
8. Remove the unit wiring diagram label (5H75033-2) from
unit and replace with wiring diagram label 5H78165 from
kit.
9. Attach the new time delay board (5H78126) to the unit
using 2 of the screws retained from step 5. Note: two of
the four holes in the new board will line up with existing
holes.
10. Using the black wiring assembly retained in step 3 above,
connect "XFMRL1" to terminal "TR1" on the new Time
Delay board.
11. Connect white wire from COM transformer terminal to
terminal board terminal XFMRL2.
12. Connect black wire from 120V transformer terminal to
terminal board terminal XFMRL1.
13. Connect red wire from 24V transformer terminal to terminal
board terminal 24 VAC.
14. Connect yellow wire from 24V transformer terminal to
terminal board terminal COM.
15. Connect one black wire from motor to terminal board
terminal TR2 and the other black motor wire to XFMRL2.
16. Connect black wire from 120V supply power to terminal
board terminal XFMRL1.
17. Connect white wire from 120V supply power to terminal
board terminal XFMRL2.
18. Plug in multi-wire connector (contains 2 black, 2 red, 1
blue and 1 orange wire) to terminal board.
19. Re-connect field wired thermostat wires to R and W.
20. Confirm that the unit is wired according to wiring diagram
5H78166 supplied with the kit.
21. Switch on the gas supply and electrical power to the unit.
22. Check the unit for proper operation.
IMPORTANT
The use of this manual is specifically intended for a qualified
installation and service agency. All installation and service of
these units must be performed by a qualified installation and
service agency. Modine manuals may contain excerpts from
component supplier literature adapted for Modine products.
Any accompanying component supplier literature is for
general information.
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. All units must be wired strictly in accordance with the
wiring diagram furnished with the kit. Any wiring different
from the wiring diagram could result in a hazard to
persons and property.
3. All wiring must be done with a wiring material having a
temperature rating of at lease 105°C.
THIS MANUAL IS THE PROPERTY OF THE OWNER.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

21
UNIT WIRING
Figure 21.1
Unit Heater Wiring Diagram (Series 101 & 102)
5H75034B2 REV D
from Lockout, Single-Phase.
Single-Stage, Hot Surface Ignition, 100% Shut-Off, Multiple Retry with Auto Reset
unit polarity.
Verify the power source and the
Use 105˚C wire for replacements. For deviations contact the factory.
in injury to the installer or user.
Combination
Gas Control
Hot Surface
Igniter
Power
Exhaust
Motor
Combination
Gas Control
Flame
Sensor
Pressure
Switch
COM
R
HH
L2
L1
R
GR(G)
BK
Y
Y
Y
R
BL
BK BK
BL
BK
BK
W
W
W
BK
XFMR
Press
Switch
Fan
Motor
TD Relay
13
H
H
Flame
Rollout
Switch
Limit
Control
Flame
Sensor
BL
W
BK
W
BK
P
Plug
BK
Hot
Surface
Igniter
O
R
R
W
Plug
Power
Exhaust
Motor W
BK
Honeywell
Combination
Gas Control
R
R
Terminal
Board
24V
115V
Xfmr
L2
(W)
L1
(BK)
Low Volt
Therm
(By
Others)
Wiring Legend
Line 24V
Factory
Field
Wire Nut
Caution
Failure to wire this unit according
to this wiring diagram may result
Note to installer:
All wiring must comply with national
electric code and all local codes.
All components must agree with
their respective power source.
Combination Gas Control
Circuit Breaker
(By Others)
Therm
t˚
TD Relay
Heater
H
H
TD Relay
Fan
Motor
1
3
TDC
UNIT HEATER WIRING DIAGRAM
Flame
Rollout
Switch
Indicates Terminal Board Connection
Limit
Control
24VAC
W
115V/60Hz/1Ø Power
Shown
115V/60Hz/1Ø Power
Circuit Breaker (By Others)
L1(BK)
L2(W)
R
Flame
Rollout
Switch
RR
Flame
Rollout
Switch
24V
120V
COM
P1
C3
C2
C1
ON
OFF
XFMR L1
COM
XFMR L2
24VAC
CW
R
Wiring Diagram Selection
Since internal or factory wiring may vary depending on controls
manufacturer, the wiring diagrams must be selected with the
series identity number when installing, servicing, or
troubleshooting a unit heater control system. Wiring diagrams
that follow are for units with the corresponding series identity
number that may be found in the 5th through the 7th digits of the
serial number. For example, a unit with the serial number
"30011023601-0981" has the 5th through the 7th digits as 102 as
shown underlined above. Match the series ID from the unit
serial plate with the series ID listed in the heading of the
following diagrams to determine which diagram corresponds to
your unit.

22
UNIT WIRING
Figure 22.1
Unit Heater Wiring Diagram (Series 103)
5H78166B REV
from Lockout, Single-Phase.
Single-Stage, Hot Surface Ignition, 100% Shut-Off, Multiple Retry with Auto Reset
unit polarity.
Verify the power source and the
Use 105˚C wire for replacements. For deviations contact the factory.
in injury to the installer or user.
Combination
Gas Control
Hot Surface
Igniter
Power
Exhaust
Motor
Combination
Gas Control
Flame
Sensor
Pressure
Switch
COM
R
HH
L2
L1
R
GR(G)
Y
Y
Y
R
BK BK
W
W
BK
XFMR
Press
Switch
Fan
Motor
Flame
Rollout
Switch
Limit
Control
Flame
Sensor
BL
W
BK
W
BK
P
Plug
BK
Hot
Surface
Igniter
O
R
R
W
Plug
Power
Exhaust
Motor W
BK
Honeywell
Combination
Gas Control
R
R
24V
115V
Xfmr
L2
(W)
L1
(BK)
Low Volt
Therm
(By
Others)
Wiring Legend
Line 24V
Factory
Field
Wire Nut
Caution
Failure to wire this unit according
to this wiring diagram may result
Note to installer:
All wiring must comply with national
electric code and all local codes.
All components must agree with
their respective power source.
Combination Gas Control
Circuit Breaker
(By Others)
Therm
t˚
TD Relay
Fan
Motor
TDC
UNIT HEATER WIRING DIAGRAM
Flame
Rollout
Switch
Indicates Terminal Board Connection
Limit
Control
24VAC
W
115V/60Hz/1Ø Power
Shown
115V/60Hz/1Ø Power
Circuit Breaker (By Others)
L1(BK)
L2(W)
R
Flame
Rollout
Switch
RR
G
TR1 TR2
Flame
Rollout
Switch
24V
120V
COM
C3
C2
C1
ON
OFF
W
R
TD
Relay
24 VAC TR2
TR1
BK
G
COM
G2
XFMR L2
XFMR L1
WBK
BK