75 537

75-537.7
5H75697B
August, 2009
Selection and installation instructions
high altitude orifice kit
model HD/HDB, HDS/HDC, PTS/BTS, and PTC
WARNING
1. All field gas piping must be pressure/leak tested prior to
operation. Never use an open flame. Use a soap solution
or equivalent for testing.
2. Gas supply shall be shut-off and the electrical power
disconnected before proceeding with the conversion.
Failure to do so could result in fire, explosion or electrical
shock.
IMPORTANT
1. The use of this manual is specifically intended for a
qualified installation and service agency. All installation
and service of these kits must be performed by a qualified
installation and service agency.
2. These instructions must also be used in conjunction with
the Installation and Service manual originally shipped with
the appliance being converted, in addition to any other
accompanying component supplier literature.
Modine gas-fired equipment ratings are certified by CSA or ETL.
For elevations above 2000 ft., ANSI Z223.1 requires ratings be
reduced 4 percent for each 1000 ft. above sea level. For units in
Canada CSA requires that ratings be reduced 10% at elevations
above 2000 ft. The high altitude kits appearing in this bulletin
are for use with units that will be installed over 2000 feet. These
kits comply with both ANSI Z223.1 and CSA requirements.
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 high altitude
kit. When converting units to propane at elevations over
2,000 ft., the main burner orifices in the propane conversion
kit must be replaced with the orifices from the “high altitude”
orifice kit. The remaining components of the propane gas kit,
other than the main burner orifices, are required to complete
the conversion to propane gas, regardless of the elevation at
which the unit is installed. For the Selection and Installation
Instructions for propane conversion kits, please see the latest
revision of Modine Bulletin 75-513 for Control Code 34 units
and 75-515 for Control Code 11 and 12 units.
Identifying the Model and Control Code
Figure 1.1 explains the model number designations. To be
convertible, the first three characters in the model number must be
HD, HDB, HDS, HDC, PTS, BTS or PTC.
After obtaining this information, refer to the proper selection
chart. The selection charts are differentiated by product type,
altitude and fuel type. If you are converting from natural gas
to propane gas and want to operate at high altitude, both a
propane conversion kit and a propane high altitude kit must
be used. Selection charts include the proper kit suffix, the orifice
drill size, and the number of orifices required for the unit being
converted. Drill sizes are also stamped on each orifice.
Figure 1.1 - Model Number Designations
HD 45 A S 01 1 1
Model Type
(Tubular HX)
HD - Power Vented
Propeller Unit
(30-125MBH)
HDB - Power Vented
Blower Unit
(60-125MBH)
HDS - Separated
Combustion
Propeller Unit
(30-125MBH)
HDC - Separated
Combustion Blower
Unit (60-125MBH)
PTS - Separated
Combustion Propeller
Unit (150-400MBH)
BTS - Separated
Combustion Blower
Unit (150-400MBH)
PTC - High Efficiency,
Separated Combustion
Propeller Unit
(135-310MBH)
Control Code
11 - Single Stage,
Natural Gas
12 - Two Stage,
Natural Gas
21 - Single Stage,
Propane Gas
22 - Two Stage,
Propane Gas
34 - Single Stage,
Natural Gas
74 - Single Stage,
Propane Gas
MBH Input
30 - 3
0,000 Btu/hr input
through
400 - 400,000 Btu/hr input
Heat Exchanger Type
A - Aluminized
S - Stainless Steel
Power Code
01 - 115 volt, 60 hertz,
single phase
Ignition Type
H - Hot Surface
S - Direct Spark
This manual is the property of the owner.
please be sure to leave it with THE OWNER when you leave the job.
Selection of the Proper Kit
Example: Convert a HDS125AS0112 for at 6000 feet elevation.
The appropriate model size is HDS125 with a Control Code of 12, which is for natural gas. Referring to Tables 2.1 through 3.2, it
can be identified that Table 2.4 should be used as it applies to HDS125 models for the elevation and gas type of this example.
In the column for 5501 - 6500 feet elevation and natural gas, it can be seen that the kit suffix is -30. All conversion kits have the same
base number, only the suffix of the part number changes by model size. The full kit number is 3H035031-30. The Item Code is 53165.
Table 2.1 - High Altitude Kits for HD/HDB 30-75 Models ONLY (7501 ft. and up in Table 2.2)
Model
Size
Kit Details
Qty per
Kit
30-75
Kit Suffix
Item Code
Orifice
Pressure Sw
5
1
U.S.A
2001-4500 ft
NAT
PROP
-1
-3
31669
31671
51
57
NA
NA
Canada
2001-4500 ft
NAT
PROP
-6
-3
34503
31671
50
57
NA
NA
4501-5500 ft
NAT
PROP
-1
-3
31669
31671
51
57
NA
NA
U.S.A. and Canada
5501-6500 ft
NAT
PROP
-1
-4
31669
31672
51
58
NA
NA
6501-7500 ft
NAT
PROP
-2
-5
31670
31673
52
59
NA
NA
Table 2.2 - High Altitude Kits for HD/HDB 30-75 Models ONLY
Model
Size
30-60
75
Kit Details
Qty per
Kit
Kit Suffix
Item Code
Orifice
Pressure Sw
Kit Suffix
Item Code
Orifice
Pressure Sw
5
1
5
1
7501-8500 ft
NAT
PROP
-2
-5
31670
31673
52
59
NA
NA
-2
-5
31670
31673
52
59
NA
NA
U.S.A. and Canada
8501 - 9500 ft
NAT
PROP
-7
-11
45406
45411
52
60
NA
NA
-8
-12
45407
45412
52
60
Yes
Yes
9501-10000 ft
NAT
PROP
-9
-13
45408
45413
53
61
NA
NA
-10
-14
45409
45414
53
61
Yes
Yes
Table 2.3 - High Altitude Kits for HDS/HDC 30-75 Models ONLY
60-75
Canada
2001-2500 ft
2501-4500 ft
NAT
PROP
NAT
PROP
-6
-1
-3
34503
31669 31671
50
51
57
NA
NA
NA
-6
-15
-17
34503
47331 47333
50
51
57
NA
Yes
Yes
-6
-16
-18
34503
47332 47334
50
51
57
NA
Yes
Yes
Not Required
45
Kit Suffix
Item Code
Orifice
Pressure Sw
Kit Suffix
Item Code
Orifice
Pressure Sw
Kit Suffix
Item Code
Orifice
Pressure Sw
U.S.A
2001-2500 ft
2501-4500 ft
NAT PROP
NAT
PROP
-1
-3
31669 31671
51
57
NA
NA
-15
-16
47331 47332
51
51
Yes
Yes
-16
-18
47332 47334
51
57
Yes
Yes
Qty
per
Kit
5
1
5
1
5
1
Not Required
30
Kit Details
Not Required
Model
Size
4501-5500 ft
NAT
PROP
-16
-18
47332
47334
51
57
Yes
Yes
-19
-20
47335
47336
51
57
Yes
Yes
-16
-18
47332
47334
51
57
Yes
Yes
U.S.A and Canada
5501-6500 ft
6501-7500 ft
NAT
PROP
NAT
PROP
-21
-22
-23
-26
47337 47338 47339 47342
51
57
52
59
Yes
Yes
Yes
Yes
-16
-18
-24
-27
47332 47334 47340 47343
51
57
52
59
Yes
Yes
Yes
Yes
-21
-22
-25
-28
47337 47338 47341 47344
51
57
52
59
Yes
Yes
Yes
Yes
Table 2.4 - High Altitude Kits for HD/HDB, HDS/HDC Model Sizes 100 and 125 (7501 ft. and up in Table 2.5)
Model
Size
100
125
Kit Details
Qty per
Kit
Kit Suffix
Item Code
Orifice
Pressure Sw
Kit Suffix
Item Code
Orifice
Pressure Sw
5
1
5
1
U.S.A
2001-4500 ft
NAT
PROP
-32
-44
53170
55577
47
1.25mm
NA
NA
-29
-34
53164
53172
43
54
NA
NA
Canada
2001-4500 ft
NAT
PROP
-31
-44
53166
55577
46
1.25mm
NA
NA
-29
-34
53164
53172
43
54
NA
NA
4501-5500 ft
NAT
PROP
-32
-44
53170
55577
47
1.25mm
NA
NA
-29
-34
53164
53172
43
54
NA
NA
U.S.A. and Canada
5501-6500 ft
NAT
PROP
-33
-36
53171
53177
48
56
NA
NA
-30
-35
53165
53176
44
54
Yes
Yes
6501-7500 ft
NAT
PROP
-39
-42
53183
53213
48
56
Yes
Yes
-37
-41
53178
53212
45
55
Yes
Yes
Table 2.5 - High Altitude Kits for HD/HDB, HDS/HDC Model Sizes 100 and 125
Model
Size
100
125
2
Kit Details
Qty per
Kit
Kit Suffix
Item Code
Orifice
Pressure Sw
Kit Suffix
Item Code
Orifice
Pressure Sw
5
1
5
1
U.S.A. and Canada
7501-8000 ft
NAT
PROP
-40
-42
53184
53213
49
56
Yes
Yes
-37
-41
53178
53212
45
55
Yes
Yes
8001 - 8500 ft
NAT
PROP
-40
-42
53184
53213
49
56
Yes
Yes
-37
-41
53178
53212
45
55
Yes
Yes
8501-9000 ft
NAT
PROP
-40
-42
53184
53213
49
56
Yes
Yes
-37
-41
53178
53212
45
55
Yes
Yes
75-537.7
9001 - 9500 ft
NAT
PROP
-40
-20
53184
47336
49
57
Yes
Yes
-38
-42
53182
53213
46
56
Yes
Yes
9501-10000 ft
NAT
PROP
-43
-20
55576
47336
50
57
Yes
Yes
-38
-42
53182
53213
46
56
Yes
Yes
Selection of the Proper Kit
Table 3.1 - High Altitude Kits for PTS/BTS Models
Model
Size
150
Kit Details
Qty per
Kit
Kit Suffix
Item Code
-
U.S.A
Canada
2001-4500 ft
NAT
PROP
-45
55776
-48
55779
U.S.A. and Canada
2001-4500 ft
NAT
PROP
-45
55776
-48
55779
4501-5500 ft
NAT
PROP
-45
55776
-48
55779
5501-6500 ft
NAT
PROP
-46
55777
-48
55779
6501-7500 ft
NAT
PROP
-47
55778
-49
55780
Orifice
6
43
54
43
54
43
54
44
54
45
55
Pressure Sw
1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Kit Suffix
Item Code
-
-50
55781
-53
55784
-50
55781
-53
55784
-51
55782
-53
55784
-51
55782
-53
55784
-52
55783
-54
55785
Orifice
Pressure Sw
7
1
43
NA
54
NA
43
NA
54
NA
44
NA
54
NA
44
NA
54
NA
45
NA
55
NA
200
Kit Suffix
Item Code
Orifice
Pressure Sw
-
-55
55786
-59
55790
-55
55786
-59
55790
-56
55787
-60
55791
-57
55788
-61
55792
-58
55789
-61
55792
7
1
41
NA
53
NA
41
NA
53
NA
42
NA
1.50mm
NA
2.35mm
NA
1.45mm
NA
2.30mm
NA
1.45mm
NA
250
Kit Suffix
Item Code
Orifice
Pressure Sw
-
-62
55793
-67
55798
-63
55794
-68
55799
-64
55795
-69
55800
-65
55796
-69
55800
-66
55797
-70
55801
9
1
42
NA
1.50mm
NA
2.40mm
NA
53
NA
2.35mm
NA
1.45mm
NA
2.30mm
NA
1.45mm
NA
43
NA
54
NA
300
Kit Suffix
Item Code
Orifice
Pressure Sw
-
-71
55802
-75
55806
-71
55802
-75
55806
-72
55803
-75
55806
-73
55804
-76
55807
-74
55805
-77
55808
9
1
37
NA
52
NA
37
NA
52
NA
38
NA
52
NA
39
Yes
1.60mm
Yes
40
Yes
53
Yes
350
Kit Suffix
Item Code
Orifice
Pressure Sw
-
-78
55809
-82
55813
-78
55809
-82
55813
-79
55810
-82
55813
-80
55811
-83
55814
-81
55812
-84
55815
12
1
2.45mm
NA
53
NA
2.45mm
NA
53
NA
2.40mm
NA
53
NA
42
NA
1.50mm
NA
2.30mm
NA
1.45mm
NA
400
Kit Suffix
Item Code
Orifice
Pressure Sw
-
-85
55816
-89
55820
-85
55816
-89
55820
-86
55817
-89
55820
-87
55818
-90
55821
-88
55819
-91
55822
12
1
37
Yes
52
Yes
37
Yes
52
Yes
38
Yes
52
Yes
39
Yes
1.60mm
Yes
40
Yes
53
Yes
175
Table 3.2 - High Altitude Kits for PTC Models
Model
Size
135
155
180
Kit Details
Qty per
Kit
U.S.A.
2001-4500 ft
Canada
2001-4500 ft
4501-5500 ft
U.S.A. and Canada
5501-6500 ft
6501-7500 ft
NAT
PROP
NAT
PROP
NAT
PROP
NAT
PROP
NAT
PROP
Kit Suffix
Item Code
-
-92
58152
-94
58154
-92
58152
-94
58154
-47
55778
-49
55780
-47
55778
-49
55780
-93
58153
-95
58155
Orifice
Pressure Sw
Kit Suffix
Item Code
6
1
-
2.15mm
NA
-45
55776
1.35mm
NA
-96
58156
2.15mm
NA
-45
55776
1.35mm
NA
-96
58156
45
NA
-45
55776
55
NA
-48
55779
45
NA
-46
55777
55
NA
-48
55779
47
NA
-46
55777
1.25mm
NA
-94
58154
1.35mm
Orifice
6
43
1.45mm
43
1.45mm
43
54
44
54
44
Pressure Sw
1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Kit Suffix
Item Code
-
-50
55781
-61
55792
-50
55781
-61
55792
-50
55781
-53
55784
-51
55782
-53
55784
-51
55782
-97
58157
1.35mm
Orifice
7
43
1.45mm
43
1.45mm
43
54
44
54
44
Pressure Sw
1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
215
Kit Suffix
Item Code
Orifice
Pressure Sw
9
1
-98
58158
-70
55801
-98
58158
-70
55801
-98
58158
-101
58161
-99
58159
-101
58161
-100
58160
-102
58162
44
NA
54
NA
44
NA
54
NA
44
NA
1.35mm
NA
2.15mm
NA
1.35mm
NA
45
NA
55
NA
260
Kit Suffix
Item Code
Orifice
Pressure Sw
9
1
-103
58163
-68
55799
-103
58163
-68
55799
-62
55793
-68
55799
-62
55793
-69
55800
-66
55797
-69
55800
41
NA
53
NA
41
NA
53
NA
42
NA
53
NA
42
NA
1.45mm
NA
43
NA
1.45mm
NA
310
Kit Suffix
Item Code
Orifice
Pressure Sw
12
1
-104
58164
-84
55815
-104
58164
-84
55815
-104
58164
-106
58166
-105
58165
-106
58166
-105
58165
-107
58167
43
NA
1.45mm
NA
43
NA
1.45mm
NA
43
NA
54
NA
44
NA
54
NA
44
NA
1.35mm
NA
75-537.7
3
HIGH ALTITUDE KIT INSTALLATION
Installation of Kit
1.Read these instructions carefully. Failure to follow
instructions can damage product or cause a hazardous
condition.
2. This conversion kit must be installed by a qualified service
person. The qualified service agency performing this work
assumes responsibility for the proper conversion of this
appliance with this kit.
3. This kit contains the following:
• High altitude gas orifices
•A conversion rating plate
•A pressure switch (some models)
4.On the High Altitude Conversion Label (see Figure 4.1) write
the drill size, as stamped on the orifice, with a permanent
marker. Be sure to check correct orifice size using the
selection instructions beginning on page 1.
Check
1. S
ee the original rating plate for the unit heater’s rated input
and verify by checking the correct main burner orifice size
and manifold pressure. This information is presented on the
conversion kit rating plate.
2. Remove the inlet and outlet pressure tap plugs and place
pressure taps on both the inlet and outlet pressure tap of the
gas valve.
3. C
onnect a pressure-measuring device capable of reading
inches of water column on both the inlet and outlet pressure
tap.
4. F
ollow lighting instructions on unit. Turn up thermostat setting
to call for heat. After the main burners light, measure the
outlet (manifold) pressure of the combination gas control.
The pressure should be 3.5" W.C. for natural gas and 10"
W.C. for propane gas. The outlet pressure can be adjusted at
the control’s regulator. Turning the adjustment clockwise will
increase the outlet pressure while turning it counterclockwise
will decrease the pressure.
6.Disconnect the gas supply piping to the heater.
5. There are no adjustments that can be made to the burner
flame. Some yellow in the flame is acceptable as long as no
carbon (black soot) is being formed.
7.Remove the electrical connections from the gas valve. This
should not require the use of tools.
6. Turn the heater off and replace the inlet and outlet pressure
tap plugs.
8.Remove the four (4) screws holding the manifold to the
burner box. This will allow for the removal of the manifold
and gas valve assembly.
7. P
lace the heater back into service and leak test the inlet and
outlet pressure tap plugs as well as the connection between
the gas valve and the manifold pipe and supply piping to the
valve.
5.Remove the access panel to the heater.
9.Remove the orifices from the manifold assembly and place
them where they can be used if the heater should need to be
converted back to natural gas.
10.Insert the orifices from the kit into the manifold assembly. If
you are converting a model size below 75 there will be extra
orifices, which should be discarded. Tighten the orifices
using a wrench so that they are gas tight.
Figure 4.1 - High Altitude Conversion Label
notice
this appliance equipped for high altitude.
11.Place the manifold assembly back on the burner box using
the four (4) screws.
In U.S. according to ansi z223.1
in canada, according to c.g.a. certification
12.Replace the electrical connections to the gas valve.
place this label adjacent to serial plate.
main burner orifices changed to
drill
size.
5H70857A
13.Verify that the igniter and sensor are in the same location
and have not been damaged.
14.Connect the gas supply piping to the heater using two
wrenches so as to not place strain on the heater gas
manifold.
15.For units requiring pressure switch change (refer to Tables
2.1 through 3.2), disconnect wires and remove screws.
Install new switch and attach wires. Note: wires are
interchangeable.
16. Affix the High Altitude Conversion Label that came with the
kit on the heater, near the serial plate on the same panel as
the common replacement parts label.
As Modine Manufacturing Company has a continuous product improvement program, it reserves the right to change design and specifications without notice.
Commercial Products Group
Modine Manufacturing Company
1500 DeKoven Avenue
Racine, WI 53403
Phone: 1.800.828.4328 (HEAT)
www.modine.com
© Modine Manufacturing Company 2009
Litho in USA
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