75-538

5H0860150000

November, 2015

SELECTION AND INSTALLATION INSTRUCTIONS

Conversion to natural or propane gas and high altitude operation

models IPT

WARNING

This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. The qualified service agency performing this work assumes responsibility for the proper conversion of this appliance with this kit.

AVERTISSEMENT

Cet ensemble de conversion ne doit etre installé que par le représentant d’un orgasnisme qualifié et conformément aux instructions du fabricant et à tous les codes et exigences applicables de l’autorité compétente. Quiconque ne respecte pas

à la lettre les instructions dans le présent manuel risque de déclencher un incendie ou une explosion entrainent des dommages matériels, des lésions corporelles ou la perte de vies humaines. L’organisme qualifié qui effectue les travaux est responsable de la conversion correcte de ce générateur d’air chaud à l’aide de cet ensemble.

IMPORTANT

This kit must be used in conjunction with literature number 9-511, latest revision, unit installation and service manual.

The kits described in this manual provide the components and instructions required for field-converting any natural gas or propane gas unit to any model size, at any listed elevation.

For Units being Converted to Natural Gas or Propane

Gas at High Altitude Concurrently

Since each kit described in this manual contains a conversion regulator kit, a separate fuel conversion kit is not necessary.

For Units being Converted from Propane Gas to

Another Propane Gas Model Size and/or Altitude

Concurrently

Follow the propane conversion instructions in this manual, discarding the propane conversion regulator kit and primary air shutter, since the original unit is already equipped with these components.

For Units Being Converted to High Altitude Operation

Gas-fired equipment ratings in the United States are certified for elevations above 2000 feet to meet ANSI Z223.1, which requires ratings to be reduced 4% for each 1000 feet above sea level. Certification in Canada requires ratings to be reduced

10% for elevations above 2000 feet. All of the high altitude kits described in this manual comply with these requirements.

To accommodate high altitude operation (over 2000 feet elevation), please follow the instructions as explained in this manual.

All gas-fired products produced by Modine Manufacturing

Company are rated at 600 feet above sea level using gas values of either 1040 Btu/ft3 for natural gas or 2500 Btu/ft3 for propane gas. Since gas values vary from location to location, be sure to account for the local gas value when sizing and selecting these products.

THIS MANUAL IS THE PROPERTY OF THE OWNER. PLEASE BE SURE

TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

2

MANIFOLD PRESSURE ADJUSTMENT

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/ft ³ .

• For Propane Gas units, 10.0" W.C. based on a gas heating value of 2,500 BTU/ft ³ .

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 vertain 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 2.1 show the standard derated heating values of natural and propane gases at various elevations.

Table 2.1 - Gas Heating Values at Altitude (Btu/ft ³)①②⑤

Altitude (ft)

0-2,000

2,001-3,000

3,001-4,000

4,001-4,500

4,501-5,000

5,001-6,000

6,001-7,000

7,001-8,000

8,001-9,000

9,001-10,000

Natural Gas

1,050

929 ③

892 ③

874 ③

856

822

789

757

727

698

Propane

2,500

2,212 ④

2,123 ④

2,080 ④

2,038

1,957

1,879

1,803

1,731

1,662

① Values 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/ft ³ value, use Equation 2.2 to calculate the required manifold pressure.

② Gas 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.

③ 945 Btu/ft ³ for Canada

④ 2,250 Btu/ft ³ for Canada

⑤ When installed at altitudes above 2,000', a pressure switch may need to be changed. Refer to Tables 3.1 and 4.1.

If the heating value of the gas being supplied is different than the values shown in Table 2.1, use the following equation to determine the appropriate manifold pressure for the altitude and gas heating value being supplied.

Equation 2.2 - Manifold Pressure for Gas Heating

Values Different Than Shown in Table 2.1

Where:

MP

ELEV

= Manifold Pressure ("W.C.) at installed elevation

BTU

TBL

= BTU/ft ³ content of gas from table 2.1

BTU

ACT

= BTU/ft company

³ content of gas obtained from the utility

MP

SL

= Manifold Pressure (in. W.C.), at Sea Level (use

3.5" W.C. for Natural Gas and 10.0" W.C. for Propane)

NOTE: Only the primary Manifold Pressure should be adjusted on units equipped with two-stage or modulating gas controls.

No adjustments to the Low Fire Manifold Pressure are necessary on these units.

Selection of the Proper High Altitude Kit

All units installed at elevations greater than 2,000 feet above sea level require a kit, in addition to potential manifold pressure adjustment outlined in the previous step. In some instances, the combustion air proving (pressure) switch may need to be changed. To determine the proper kit to use, refer to Table

3.1 and 4.1. An example is shown as a guide to the proper selection of the kit and whether a pressure switch change is required.

75-538

MODEL IDENTIFICATION / NATURAL GAS TO PROPANE GAS CONVERSION

Table 3.1 - Convert to Natural Gas

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

50

0-2000

77823

60

0-2000

77824

75

0-6500

77825

100

0-7500

77826

125

0-7500

77827

150

0-7500

77828

175

0-7500

77829

200

0-7500

77830

3H037840-1 3H037840-2 3H037840-3 3H037840-4 3H037840-5 3H037840-6 3H037840-7 3H037840-8

3.3 mm 27 22 11 3 B F L

"50" "60" "75" "100" "125" "150N" "175" "200"

Pressure Switch /Label Color

Primary Air Plate Diameter

Regulator Kit for WR 36J Valve

Conversion Label

5H081908-5

Orange

5H081908-1

Violet

5H081908-9

Tan

5H081908-9

Tan

5H081908-4

Yellow

5H081908-1

Violet

5H081908-1

Violet

5H081908-6

Aqua

None None 0.875

0.875

0.875

92-0656 92-0656 92-0656 92-0656 92-0656

5H086014 5H086014 5H086014 5H086014 5H086014

0.875

92-0656

None

92-0656

None

92-0656

5H086014 5H086014 5H086014

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

Pressure Switch /Label Color

Primary Air Plate Diameter

Regulator Kit for WR 36J Valve

Conversion Label

50 60 75

2001-5000 2001-3500 6501-7500

77831 77832 77837

3H037840-9 3H037840-10 3H037840-15

3.3 mm 27 22

"50" "60" "75"

5H081908-1

Violet

5H081908-6

Aqua

5H081908-4

Yellow

None

92-0656

None

92-0656

0.875

92-0656

5H086014 5H086014 5H086014

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

Pressure Switch /Label Color

Primary Air Plate Diameter

Regulator Kit for WR 36J Valve

Conversion Label

50 60

5001-7500 3501-6000

77836 77834

3H037840-14 3H037840-12

3.3 mm

"50"

27

"60"

5H081908-6

Aqua

5H081908-8

Sungold

None

92-0656

None

92-0656

5H086014 5H086014

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

Pressure Switch /Label Color

Primary Air Plate Diameter

Regulator Kit for WR 36J Valve

Conversion Label

60

6001-7500

77838

3H037840-16

27

"60"

5H081908-7

Grey

None

92-0656

5H086014

75-538 3

4

MODEL IDENTIFICATION / PROPANE GAS TO NATURAL GAS CONVERSION

Table 4.1 - Convert to Propane

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

50

0-2000

77839

60

0-5000

77840

75

0-5000

77841

100

0-5000

77842

125

0-7500

77843

150

0-7500

77844

175

0-7500

77845

200

0-6000

77846

3H037841-1 3H037841-2 3H037841-3 3H037841-4 3H037841-5 3H037841-6 3H037841-7 3H037841-8

2.0 mm 43 38 32 30 28 23 18

"50" "60" "75" "100" Yes "150P" "175" "200"

Pressure Switch /Label Color

Primary Air Plate Diameter

Primary Air Shutter

Regulator Kit for WR 36J Valve

Conversion Label

5H081908-5

Orange

5H081908-1

Violet

5H081908-3

White

5H081908-9

Tan

5H081908-4

Yellow

5H081908-1

Violet

5H081908-1

Violet

5H081908-5

Orange

None

Yes

None

Yes

0.875

Yes

0.875

Yes

0.875

Yes

0.875

Yes

None

Yes

None

Yes

92-0659 92-0659 92-0659 92-0659 92-0659 92-0659 92-0659 92-0659

5H086014 5H086014 5H086014 5H086014 5H086014 5H086014 5H086014 5H086014

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

Pressure Switch /Label Color

Primary Air Plate Diameter

Primary Air Shutter

Regulator Kit for WR 36J Valve

Conversion Label

50 60 75 100 200

2001-5000 5001-6000 5001-7500 5001-7500 6001-7500

77847 77851 77852 77853 77855

3H037841-9 3H037841-13 3H037841-14 3H037841-15 3H037841-17

2.0 mm 43 38 32 18

"50" "60" "75" "100" "200"

5H081908-1

Violet

5H081908-8

Sungold

5H081908-2

Pink

5H081908-4

Yellow

5H081908-6

Aqua

None

Yes

92-0659

None

Yes

92-0659

0.875

Yes

92-0659

0.875

Yes

92-0659

None

Yes

92-0659

5H086014 5H086014 5H086014 5H086014 5H086014

Model Size

Altitude Range (FT)

Kit Item Code

Kit Part Number

Gas Orifice Drill Size

Air Restrictor Plate Label

Pressure Switch /Label Color

Primary Air Plate Diameter

Primary Air Shutter

Regulator Kit for WR 36J Valve

Conversion Label

50 60

5001-7500 6001-7500

77850 77854

3H037841-12 3H037841-16

2.0 mm 43

"50" "60"

5H081908-6

Aqua

5H081908-7

Grey

None

Yes

None

Yes

92-0659 92-0659

5H086014 5H086014

75-538

G

H

SELECTION

Identifying the Model and Control Code

Figure 5.1 explains the unit model number found on the unit's serial plate. Markings pertinent to verifying correct application of the coversion kits are identified and explained in detail. All of the following prerequisites must be satisfied before the unit is deemed convertible.

D

E

F

A

B

C

1. The first character in the model number must be IPT.

1

Figure 5.1

5 6 7

DIGIT SEQUENCE 1, 2, 3 4, 5, 6 7 8, 9 10, 11

MODEL NUMBER

IPT 200 S 01 11

MODEL PREFIX:

IMPROVED PRESSURE TUBE: IPT

CONTROL CODE:

11: SINGLE STAGE, NATURAL GAS

MODEL SIZE:

MBH INPUT: 50, 60, 75, 100, 125, 150, 175, 200

IGNITION TYPE:

S: DIRECT SPARK

21: SINGLE STAGE, PROPANE GAS

POWER CODE:

01: 115V/60HZ/1PH

8

Selection of the Proper Kit

DIGIT SEQUENCE 1 17, 18, 19, 20, 21

SERIAL NUMBER

2, 3 3, 4 5, 6 7, 8 9, 10 11, 12 13, 14, 15, 16

IMPORTANT

This kit must be used in conjunction with literature number 9-511, latest revision, unit installation and service manual.

SPO NUMBER

SEQUENTIAL NUMBER

NUMBER VARIES FROM 0000 TO 9999.

UNIT SERIES:

00: ORIGINAL, 01: MODIFIED

CONTROL SUPPLIER:

01: ROBERTSHAW, 09: WHITE ROGERS,

05: HONEYWELL, 17: UNITED TECH, 08: FENWAL

EACH UNIT WITHIN SAME WEEK OF

MANUFACTURE IS TO HAVE UNIQUE NUMBER

YEAR OF MANUFACTURE

WEEK OF MANUFACTURE

SAME AS REQUIREMENTS

PLANNING SHOP CALENDER

Referring to the model number on the unit serial plate, select the appropriate kit from Tables 3.1 - 4.1.

Example:

To convert a IPT 75AS0111 to propane gas operation at 6000 feet, select Item Code #77852. (The new IPT 75AS0121 requires tube system lengths of either 20 or 30 feet.)

1 3 4 5 6 7

To convert a IPT 75AS0111 to 150 MBH on propane gas at

5000 feet, select Item Code # 77844. (The new IPT 150AS0121 requires tube system lengths of either 50 or 60 feet.)

8

Note:

For BTU conversions - 50 and 60 can only be converted to 50 or 60K BTU. 75-200 can only be converted between 75-200

BTU sizes.

9 10 11 12

A

B

C

D

E

F

.

REVISION

.

DESCRIPTION

MODINE MANUFACTURING COMPANY

1500 DE KOVEN AVENUE

RACINE, WISCONSIN 53403-2552

.

BY

.

DATE

.

.

CO NUMBER FIELD

THIS PRINT AND ITS CONTENTS ARE THE PROPERTY OF MODINE AND MUST NOT BE USED

FOR ANY PURPOSE NOT AUTHORIZED BY MODINE. DO NOT DISCLOSE, REPRODUCE OR

OTHERWISE USE THIS PRINT OR ITS CONTENTS IN ANY MANNER DETRIMENTAL TO THE

INTEREST OF MODINE WITHOUT MODINE'S PRIOR WRITTEN CONSENT. MODINE RESERVES

ALL RIGHTS OF DESIGN AND INVENTION TO THE EXTENT PERMITTED BY LAW.

CORE CODE NUMBER MATERIAL SURFACE

TEXTURE

GENERAL TOLERANCE

UNLESS NOTED

AUTHOR

CHECKED

APPROVED

STANDARD

DATE

19Jun15

28Feb14 CPG aingle

28Feb14 CPG BRS

1ST ANGLE

3RD ANGLE

SIMILAR TO: N/A

DEP

CPG aingle

NAME

CAD SYSTEM

SOLID EDGE

SCALE

UNITS

IN

DRAWING NUMBER

8H0075610000

DESCRIPTION

FORMAT

A2

REPLACES: N/A CAD MODEL NUMBER:

UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES.

8H0075610000.dft

2 PLC = u.03

3 PLC = u.005

ANGLES = u1v

SERIAL PLATE MARKING SHEET

IPT, LOW INTENSITY INFRARED

PAGE OF 1

G

H

75-538 5

6

INSTALLATION

Installation of Kit

Conversion of any unit is the responsibility of, and the risk of the person making the conversion.

CAUTION

Gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.

Failure to do so could result in fire, explosion or electrical shock.

Figure 6.2 - Propane Gas Air Shutter and Orifice

Air Shutter

General

1. Ensure gas supply and electrical power disconnections have been made.

2. Remove burner box side access panel (two screws).

3. Remove burner enclosure panel.

4. Remove the single screw and discard the primary air plate shown in Figure 6.1. Models 50-60 and 175-200 NG and LP units do not have a primary air plate.

Figure 6.1 - Natural Gas Primary Air Plate

Primary Air

Plate

Orifice

8. Insert propane gas orifice into manifold. Refer to Tables 3.1

- 4.1 for correct gas orifice drill size. Tighten propane gas orifice using a wrench and ensure that it is gas-tight.

9. Tighten the burner support bracket and replace the burner enclosure panel.

10. Remove the air intake restrictor plate from teh combustion blower inlet by removing four screws. Refer to Figure 6.3 for location of restrictor plate.

Figure 6.3 - Air Restrictor Plate

Air

Restrictor

Plate

Single Screw

Burner Support

Bracket

Burner

Enclosure

5. Loosen the screws for the burner support bracket (see

Figure 6.1) to make clearance for the natural gas orifice removal.

6. Remove original gas orifice from the manifold and discard.

7. Slip the propane gas air shutter over the propane gas orifice and tighten. The air shutter flat side should be flush with the end of the propane gas orifice, as shown in Figure

6.2. Propane air shutters are only used on 75-200 models.

Combustion

Blower

11. Install propane intake air restrictor plate. The air restrictor plate number is stamped onto the restrictor plate. Refer to

Table 3.1 - 4.1 to verify the correct restrictor plate.

75-538

INSTALLATION

12. Remove the unit's pressure switch by removing the pressure hose, the two wire leads, and two mounting screws. See Figure 7.1.

Figure 7.1 - Pressure Switch

Hose

A

1

Figure 7.3

2

Conversion Rating Plate

B

3

Primary Air

Plate

C

D

13. Install the new pressure switch. Ensure that the hose and two wire leads are properly connected to the pressure switch. Refer to Tables 3.1 - 4.1 to verify the correct pressure switch part number and label color.

E

If the original unit is a natural gas model, proceed to #14 below.

If the original unit is a propane gas model, proceed to #16 below.

14. Modify the combination gas control to use propane gas by following the instructions in the regulator kit. Some conversion kits will have more than one regulator kit, specific to the manufacturer of hte combination gas control

F

(i.e. Honeywell, Robertshaw, etc.). Check the conversion kit parts list, Tables 3.1 - 4.1, for application of the correct regulator kit. A second check can be made by finding the model number on the combination gas control and matching it with the correct kit. Do not attempt to substitute one regulator kit for another.

15. Affix the appropriate propane conversion label (see

Figure 7.2) to the gas valve. This label is supplied with the regulator conversion kit.

Figure 7.2

Typical Combination Gas Control Conversion

ATTENTION

THIS VALVE HAS BEEN

CONVERTED FOR USE

WITH

LP GAS

ATTENTION

Cette soupage a

été convertie pour l’ usage de gaz L.P.

16. Affix the propane conversion rating plate (see Figure 7.3) adjacent to the unit's original rating plate.

75-538

1 2 3

4

4

5 6 7 8

1. Made from 8H0704200002 label stock and 8H0704300000. Marking system described below. Label stock is 3.94" width X 8.50" height.

2. Label design and marking printed directly by Modine using Printronix

T5308 printer and system consisting of the following two elements:

a) Unprinted polyester film coated on on side with pressure sensitive adhesive protected by a release liner (8H070420002) b) Resin ribbon, black.

3. Label design based on artworks from this print. Layouts to be stored as

Loftware files to be used by batch printing applications.

4. Pressure sensitive marking system: BLM 229.

5. All artwork to be imported to Loftware directly from electronic file.

Preferred format is *.pcx, 300dpi, monocrome.

6. Label shown is scanned from original label. Two labels can be printed on

3.94" W X 8.50" h label stock. Loftware design file must be updated when this file is updated.

7. Variable fields are shown in blocks.

8. Print file saved in \\raciwi-u1\loftware$\labels directory.

Image file saved in \\raciwi-u\loftware$\images directory.

A

B

C

D

.

REVISION

.

DESCRIPTION

.

BY

.

DATE

.

.

CO NUMBER FIELD

MODINE MANUFACTURING COMPANY

RACINE, WISCONSIN 53403-2552

AUTHOR

CHECKED

APPROVED

STANDARD

DATE DEP NAME

27Aug15

27Aug15

27Aug15

BHVAC DLC

BHVAC DLC

BHVAC ANI

1ST ANGLE

CAD SYSTEM

SOLID EDGE

SCALE

UNITS

IN

FORMAT

THIS PRINT AND ITS CONTENTS ARE THE PROPERTY OF MODINE AND MUST NOT BE USED

FOR ANY PURPOSE NOT AUTHORIZED BY MODINE. DO NOT DISCLOSE, REPRODUCE OR

OTHERWISE USE THIS PRINT OR ITS CONTENTS IN ANY MANNER DETRIMENTAL TO THE

INTEREST OF MODINE WITHOUT MODINE'S PRIOR WRITTEN CONSENT. MODINE RESERVES

ALL RIGHTS OF DESIGN AND INVENTION TO THE EXTENT PERMITTED BY LAW.

CORE CODE NUMBER MATERIAL SURFACE

TEXTURE

GENERAL TOLERANCE

UNLESS NOTED

SEE NOTE

DRAWING NUMBER

2 PLC = u.03

3 PLC = u.005

5H0860140000

DESCRIPTION

3RD ANGLE

SIMILAR TO: N/A

A3

REPLACES: N/A CAD MODEL NUMBER:

UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS ARE IN INCHES.

5H0860140000.dft

ANGLES = u1v

CONVERSION KIT RATING PLATE

PAGE

8

1 OF 1

E

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7

8

INSTALLATION / CHECK-OUT PROCEDURE

17. Verify that all controls and wiring have not been damaged, then replace the burner box side access panel.

WARNING

Radiant tube baffle must be properly selected from Table 8.1 according to fuel type, burner input and tube system length. It must also be properly assembled and installed.

Figure 8.2 - Baffle Insertion

Reflector

Last Tube

18. The last section of radiant tube includes a turbulating baffle, which must be assembled from the three identical sections provided with the tubes. Select the appropriate number of sections from Table 8.1 - noting that some models have different numbers of sections for natural and propane gas and fasten them together end-to-end as shown in Figure

8.1. Insert the assembled baffle into the last tube section, flush with the end of the tube closest to the vent as shown in Figure 8.2, and discard any unused baffle sections.

19. Continue with the following Check-Out Procedure.

50

60

75

100

125

150

175

200

Input

MBH

LP

NG

LP

NG

LP

NG

LP

Nat

Prop

NG

LP

NG

LP

NG

LP

NG

Table 8.1 - Baffle Section Quantity Determination

-

-

-

4

-

1

3

20

2

3

4

-

-

-

-

-

-

-

-

-

-

-

-

4

-

-

2

4

1

1

1

2

Tube System Length (ft.)

30

2

40

-

50

-

60

-

-

0

0

2

-

-

-

-

-

-

-

3

3

4

-

3

-

2

3

-

2

-

2

1

-

-

-

-

-

-

-

-

3

3

3

3

4

4

2

2

2

2

2

2

-

-

-

-

-

-

-

70

-

-

-

-

-

2

0

0

0

Figure 8.1 - Baffle Section Fastening Detail

Tabs

Baffle

Check-Out Procedure

This is an abbreviated check-out procedure. For additional detail, please see applicable installation and service manual for the appropriate unit.

1. Place pressure taps on both the inlet and outlet pressure taps of the gas valve.

2. Connect a pressure-measuring device capable of reading inches of water column on both the inlet and outlet pressure taps.

3. Restore both the fuel supply and the electrical supply to the unit. Verify the proper ignition sequence. The inlet pressure must be 12"-14" water column. The manifold pressure must be 10" water column.

4. No adjustments can be made to the burner flame. Some yellow in the flame is acceptable as long as no carbon

(black soot) is being formed.

5. Verify the input rate by checking the correct main burner orifice sie and manifold pressure. This information is presented on the conversion kit rating plate.

6. Turn the unit off and replace the inlet and outlet pressure tap plugs.

7. Turn the unit on.

8. Check for leaks at all joints, pressure tap plugs, and connections in the gas lines. This is most easily done with a soap and water solution. Simply brush or spray some of the solution on a joint or connection, and look for bubble formation.

9. If additional information is required, please refer to applicable installation and service manual for the specific infrared model.

Slots

75-538

Modine Manufacturing Company • 1500 DeKoven Avenue • Racine, Wisconsin 53403-2552

Tel: 1.800.828.4328 (HEAT) • www.modine.com

© Modine Manufacturing Company 2015

75-538

5/03 - Litho in USA

9