Modine Manufacturing HD45 Selection And Installation Instructions

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) 75-537.7 5H75697B 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. 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. Selection and installation instructions high altitude orifice kit model HD/HDB, HDS/HDC, PTS/BTS, and PTC August, 2009 This manual is the property of the owner. please be sure to leave it with THE OWNER when you leave the job. 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. 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. IMPORTANT Figure 1.1 - Model Number Designations HD 45 A S 01 1 1 Power Code 01 - 115 volt, 60 hertz, single phase Ignition Type H - Hot Surface S - Direct Spark Heat Exchanger Type A - Aluminized S - Stainless Steel MBH Input 30 - 30,000 Btu/hr input through 400 - 400,000 Btu/hr input 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

Table 2.2 - High Altitude Kits for HD/HDB 30-75 Models ONLY 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. 75-537.7 Model Size Kit Details Qty per Kit U.S.A Canada U.S.A. and Canada 2001-4500 ft 2001-4500 ft 4501-5500 ft 5501-6500 ft 6501-7500 ft NAT PROP NAT PROP NAT PROP NAT PROP NAT PROP 30-75 Kit Suffix - -1 -3 -6 -3 -1 -3 -1 -4 -2 -5 Item Code - 31669 31671 34503 31671 31669 31671 31669 31672 31670 31673 Orifice 5 51 57 50 57 51 57 51 58 52 59 Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA Model Size Kit Details Qty per Kit U.S.A. and Canada 7501-8500 ft 8501 - 9500 ft 9501-10000 ft NAT PROP NAT PROP NAT PROP 30-60 Kit Suffix - -2 -5 -7 -11 -9 -13 Item Code - 31670 31673 45406 45411 45408 45413 Orifice 5 52 59 52 60 53 61 Pressure Sw 1 NA NA NA NA NA NA 75 Kit Suffix - -2 -5 -8 -12 -10 -14 Item Code - 31670 31673 45407 45412 45409 45414 Orifice 5 52 59 52 60 53 61 Pressure Sw 1 NA NA Yes Yes Yes Yes Table 2.3 - High Altitude Kits for HDS/HDC 30-75 Models ONLY Model Size Kit Details Qty per Kit U.S.A Canada 2001-2500 ft 2501-4500 ft 2001-2500 ft 2501-4500 ft NAT PROP NAT PROP NAT PROP NAT PROP 30 Kit Suffix - Not Required Not Required -1 -3 -6 Not Required -1 -3 Item Code - 31669 31671 34503 31669 31671 Orifice 5 51 57 50 51 57 Pressure Sw 1 NA NA NA NA NA 45 Kit Suffix - -15 -16 -6 -15 -17 Item Code - 47331 47332 34503 47331 47333 Orifice 5 51 51 50 51 57 Pressure Sw 1 Yes Yes NA Yes Yes 60-75 Kit Suffix - -16 -18 -6 -16 -18 Item Code - 47332 47334 34503 47332 47334 Orifice 5 51 57 50 51 57 Pressure Sw 1 Yes Yes NA Yes Yes U.S.A and Canada 4501-5500 ft 5501-6500 ft 6501-7500 ft NAT PROP NAT PROP NAT PROP -16 -18 -21 -22 -23 -26 47332 47334 47337 47338 47339 47342 51 57 51 57 52 59 Yes Yes Yes Yes Yes Yes -19 -20 -16 -18 -24 -27 47335 47336 47332 47334 47340 47343 51 57 51 57 52 59 Yes Yes Yes Yes Yes Yes -16 -18 -21 -22 -25 -28 47332 47334 47337 47338 47341 47344 51 57 51 57 52 59 Yes Yes 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) Table 2.5 - High Altitude Kits for HD/HDB, HDS/HDC Model Sizes 100 and 125 Model Size Kit Details Qty per Kit U.S.A Canada U.S.A. and Canada 2001-4500 ft 2001-4500 ft 4501-5500 ft 5501-6500 ft 6501-7500 ft NAT PROP NAT PROP NAT PROP NAT PROP NAT PROP 100 Kit Suffix - -32 -44 -31 -44 -32 -44 -33 -36 -39 -42 Item Code - 53170 55577 53166 55577 53170 55577 53171 53177 53183 53213 Orifice 5 47 1.25mm 46 1.25mm 47 1.25mm 48 56 48 56 Pressure Sw 1 NA NA NA NA NA NA NA NA Yes Yes 125 Kit Suffix - -29 -34 -29 -34 -29 -34 -30 -35 -37 -41 Item Code - 53164 53172 53164 53172 53164 53172 53165 53176 53178 53212 Orifice 5 43 54 43 54 43 54 44 54 45 55 Pressure Sw 1 NA NA NA NA NA NA Yes Yes Yes Yes Model Size Kit Details Qty per Kit U.S.A. and Canada 7501-8000 ft 8001 - 8500 ft 8501-9000 ft 9001 - 9500 ft 9501-10000 ft NAT PROP NAT PROP NAT PROP NAT PROP NAT PROP 100 Kit Suffix - -40 -42 -40 -42 -40 -42 -40 -20 -43 -20 Item Code - 53184 53213 53184 53213 53184 53213 53184 47336 55576 47336 Orifice 5 49 56 49 56 49 56 49 57 50 57 Pressure Sw 1 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 125 Kit Suffix - -37 -41 -37 -41 -37 -41 -38 -42 -38 -42 Item Code - 53178 53212 53178 53212 53178 53212 53182 53213 53182 53213 Orifice 5 45 55 45 55 45 55 46 56 46 56 Pressure Sw 1 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

3 75-537.7 Table 3.1 - High Altitude Kits for PTS/BTS Models Table 3.2 - High Altitude Kits for PTC Models Model Size Kit Details Qty per Kit U.S.A Canada U.S.A. and Canada 2001-4500 ft 2001-4500 ft 4501-5500 ft 5501-6500 ft 6501-7500 ft NAT PROP NAT PROP NAT PROP NAT PROP NAT PROP 150 Kit Suffix - -45 -48 -45 -48 -45 -48 -46 -48 -47 -49 Item Code - 55776 55779 55776 55779 55776 55779 55777 55779 55778 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 175 Kit Suffix - -50 -53 -50 -53 -51 -53 -51 -53 -52 -54 Item Code - 55781 55784 55781 55784 55782 55784 55782 55784 55783 55785 Orifice 7 43 54 43 54 44 54 44 54 45 55 Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 200 Kit Suffix - -55 -59 -55 -59 -56 -60 -57 -61 -58 -61 Item Code - 55786 55790 55786 55790 55787 55791 55788 55792 55789 55792 Orifice 7 41 53 41 53 42 1.50mm 2.35mm 1.45mm 2.30mm 1.45mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 250 Kit Suffix - -62 -67 -63 -68 -64 -69 -65 -69 -66 -70 Item Code - 55793 55798 55794 55799 55795 55800 55796 55800 55797 55801 Orifice 9 42 1.50mm 2.40mm 53 2.35mm 1.45mm 2.30mm 1.45mm 43 54 Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 300 Kit Suffix - -71 -75 -71 -75 -72 -75 -73 -76 -74 -77 Item Code - 55802 55806 55802 55806 55803 55806 55804 55807 55805 55808 Orifice 9 37 52 37 52 38 52 39 1.60mm 40 53 Pressure Sw 1 NA NA NA NA NA NA Yes Yes Yes Yes 350 Kit Suffix - -78 -82 -78 -82 -79 -82 -80 -83 -81 -84 Item Code - 55809 55813 55809 55813 55810 55813 55811 55814 55812 55815 Orifice 12 2.45mm 53 2.45mm 53 2.40mm 53 42 1.50mm 2.30mm 1.45mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 400 Kit Suffix - -85 -89 -85 -89 -86 -89 -87 -90 -88 -91 Item Code - 55816 55820 55816 55820 55817 55820 55818 55821 55819 55822 Orifice 12 37 52 37 52 38 52 39 1.60mm 40 53 Pressure Sw 1 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Model Size Kit Details Qty per Kit U.S.A. Canada U.S.A. and Canada 2001-4500 ft 2001-4500 ft 4501-5500 ft 5501-6500 ft 6501-7500 ft NAT PROP NAT PROP NAT PROP NAT PROP NAT PROP 135 Kit Suffix - -92 -94 -92 -94 -47 -49 -47 -49 -93 -95 Item Code - 58152 58154 58152 58154 55778 55780 55778 55780 58153 58155 Orifice 6 2.15mm 1.35mm 2.15mm 1.35mm 45 55 45 55 47 1.25mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 155 Kit Suffix - -45 -96 -45 -96 -45 -48 -46 -48 -46 -94 Item Code - 55776 58156 55776 58156 55776 55779 55777 55779 55777 58154 Orifice 6 43 1.45mm 43 1.45mm 43 54 44 54 44 1.35mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 180 Kit Suffix - -50 -61 -50 -61 -50 -53 -51 -53 -51 -97 Item Code - 55781 55792 55781 55792 55781 55784 55782 55784 55782 58157 Orifice 7 43 1.45mm 43 1.45mm 43 54 44 54 44 1.35mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 215 Kit Suffix - -98 -70 -98 -70 -98 -101 -99 -101 -100 -102 Item Code - 58158 55801 58158 55801 58158 58161 58159 58161 58160 58162 Orifice 9 44 54 44 54 44 1.35mm 2.15mm 1.35mm 45 55 Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 260 Kit Suffix - -103 -68 -103 -68 -62 -68 -62 -69 -66 -69 Item Code - 58163 55799 58163 55799 55793 55799 55793 55800 55797 55800 Orifice 9 41 53 41 53 42 53 42 1.45mm 43 1.45mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA 310 Kit Suffix - -104 -84 -104 -84 -104 -106 -105 -106 -105 -107 Item Code - 58164 55815 58164 55815 58164 58166 58165 58166 58165 58167 Orifice 12 43 1.45mm 43 1.45mm 43 54 44 54 44 1.35mm Pressure Sw 1 NA NA NA NA NA NA NA NA NA NA

Commercial Products Group Modine Manufacturing Company 1500 DeKoven Avenue Racine, WI 53403 Phone: 1.800.828.4328 (HEAT) www.modine.com Litho in USA HIGH ALTITUDE KIT INSTALLATION Figure 4.1 - High Altitude Conversion Label notice this appliance equipped for high altitude. In U.S. according to ansi z223.1 in canada, according to c.g.a. certification main burner orifices changed to place this label adjacent to serial plate. 5H70857A drill size. 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. 5. Remove the access panel to the heater. 6. Disconnect the gas supply piping to the heater. 7. Remove the electrical connections from the gas valve. This should not require the use of tools. 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. 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. 11. Place the manifold assembly back on the burner box using the four (4) screws. 12. Replace the electrical connections to the gas valve. 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. Installation of Kit Check 1. See 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. Connect a pressure-measuring device capable of reading inches of water column on both the inlet and outlet pressure tap. 4. Follow 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. 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. 6. Turn the heater off and replace the inlet and outlet pressure tap plugs. 7. Place 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. © Modine Manufacturing Company 2009