IPT Installation Manual

ManualsBrandsModine ManualsHeatingIPT - 60k BTU - Infrared Unit Heater - NG - Low Intensity - 115V - 40 Foot U-Tube

February, 2019

INSTALLATION AND SERVICE MANUAL

low intensity gas-red pressurized infrared heaters

model IPT

9-511.4

5H0819050000

THIS MANUAL IS THE PROPERTY OF THE OWNER.

PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.

Inspection upon Arrival

1. Inspect unit upon arrival. In case of damage, report it

immediately to transportation company and your local Modine

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 upon arrival for conformance with description of

product ordered (including specifications where applicable).

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. Do not locate ANY gas-fired units in areas

where chlorinated, halogenated, or acidic

vapors are present in the atmosphere.

These substances can cause premature

heat exchanger failure due to corrosion

which can cause property damage, serious

injury or death.

3. For either indoor or outdoor installation.

Not for use in residential dwellings.

FOR YOUR SAFETY

IF YOU SMELL GAS:

1. Open windows (indoor installation only).

2. Do not touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open

containers in the vicinity of this unit is

hazardous.

IMPORTANT

The use of this manual is specifically intended

for a qualified installation and service agency.

A qualified installation and service agency

must perform all installation and service of

these appliances.

CAUTION

As with all infrared equipment, clearances to

combustible materials are critical. Be sure all

units have reflectors installed along the

entire length of the tube, and that they are not

mounted at an angle greater than 45° from

the horizontal plane. In locations used for

storage of combustible materials, signs shall

be clearly posted in the vicinity of the heater

where readily apparent to material handlers

to specify the maximum permissible stacking

height to maintain required clearances from the

heater to the combustibles.

WARNING

Summary of content (28 pages)

PAGE 1
9-511.4 5H0819050000 February, 2019 INSTALLATION AND SERVICE MANUAL low intensity gas-fired pressurized infrared heaters model IPT FOR YOUR SAFETY WARNING 1. I mproper 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.
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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. 2. 3. 4.
PAGE 3
SI (METRIC) CONVERSION FACTORS/UNIT LOCATION IMPORTANT Table 3.1 - SI (Metric) Conversion Factors To Convert Multiply By To Obtain "W.C. 0.249 kPa °F (°F-32) x 5/9 °C Btu 1.06 kJ Btu/ft3 37.3 kJ/m3 Btu/hr 0.000293 kW CFH (ft3/hr) 0.000472 m3/min CFH (ft3/hr) 0.00000787 m3/s CFM (ft3/min) 0.0283 m3/min CFM (ft3/min) 0.000472 m3/s 1.
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UNIT LOCATION /AIR REQUIREMENTS Location Recommendations 1. When locating the heater, consider the general space and heating requirements and availability of gas and electrical supply. 2. Be sure the structural support and chain at the unit location is adequate to support the weight of the unit. 3. Be sure that the minimum clearances to combustible materials and are maintained. The minimum clearances to combustibles are shown in Table 4.1, and Figures 4.1 and 4.
PAGE 5
INSTALLATION Rotation of Gas Control Unit Mounting – Pre-Installation Notes WARNING WARNING 1. To prevent risk of fire or improper unit operation, radiant tube baffle must be properly selected from Table 10.1 according to fuel type, burner input, and tube system length and it must also be properly assembled and installed. 2. To prevent tube sections from separating during unit operation, tube clamps must be centered over the joints of adjoining tube sections and tightened to 50 ft. - lb.
PAGE 6
INSTALLATION Figure 6.1 - Straight Tube System Components Ref # Part Description 1 Burner 2 Burner Support Bracket (Qty. 4) 3 Tube Clamp 4 Tube & Reflector Hanger w/ Reinforcing Bar 5 Radiant Tube 6 Tube & Reflector Hanger 7 Reflector 8 Reflector End Cap 9 Turbulator Baffle Table 6.1 - Straight Tube System Component List Tube Length Available Burner (ft.
PAGE 7
INSTALLATION Figure 7.1 - U-Tube System Components Ref # Part Description 1 Burner 2 Burner Support Bracket (Qty. 4) 3 Tube Clamp 4 Double Tube & Reflector Hanger w/ Reinforcing Bar 5 Radiant Tube 6 Double Tube & Reflector Hanger 7 U-Tube 8 Reflector 9 Reflector End Cap 10 Turbulator Baffle Table 7.1 - U-Tube System Component List Tube Double-Tube Double-Tube Turbulator Length Available Burner 5' 10' 10' Hangers with Hangers Tube Reflector Baffle (ft.
PAGE 8
INSTALLATION Unit Mounting – Tube System WARNING To prevent tube sections from separating during unit operation, tube clamps must be centered over the joints of adjoining tube sections and tightened to 50 ft. - lb. and the clamp fastened to the tubes using (2) self-tapping screws. Failure to do so may result in separation of tube sections which could fall and result in death or serious injury. For steps 1-8 of this section, please refer to Figures 8.1 and 9.1 1.
PAGE 9
INSTALLATION Figure 9.1 - U-Tube System Suspension Ref # Part Description 1 Burner (installed In later steps) 2 Turbulator Baffle 3 Chain & “S” Hooks 4 Radiant Tube 5 DBL Tube & Reflector Hanger w/ Reinforcing Bar 6 Tube Clamp 7 Double Tube & Reflector Hanger 8 U-Tube 9 Self-Tapping Sheet Metal Screws Table 9.
PAGE 10
INSTALLATION 3. I nsert the completed turbulator baffle assembly into the last radiant tube, flush with the end as shown in Figure 10.2. Unit Mounting – Turbulator Baffle WARNING Figure 10.2 - Insertion of Turbulator Baffle Assembly To prevent risk of fire or improper unit operation, radiant tube baffle must be properly selected from Table 10.1 according to fuel type, burner input, and tube system length and it must also be properly assembled and installed. Reflector Last Tube 1.
PAGE 11
INSTALLATION Unit Mounting – Radiant Reflector CAUTION As with all infrared equipment, clearances to combustible materials are critical. Be sure all units have reflectors installed along the entire length of the tube, and that they are not mounted at an angle greater than 45° from the horizontal plane.
PAGE 12
INSTALLATION Venting Figure 12.2 - Vertical Venting WARNING 2' Min. Approved cap 1. A built-in combustion air blower is provided – additional external draft hoods (diverters) or power exhausters are not required or permitted. 1' Min.* CAUTION See Figure 12.2 Installation must conform with local building codes or in the absence of local codes, with Part 7, Venting of Equipment, or the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) – latest edition.
PAGE 13
INSTALLATION Figure 13.1 - Vertical Venting through Sloped Roof 3. The vent system shall terminate at least 3' above any forced air inlet (except direct vent units) located within 10', and at least 4' below, 4' horizontally from, or 1' 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' above grade; whichever is greater.
PAGE 14
INSTALLATION CAUTION Utilizing Outside Combustion Air (Optional) 1. An accessory combustion air intake collar is required for connecting the combustion air piping to the burner box. For outdoor installation, the air intake collar connects directly to the accessory air intake cap. 2. All units may utilize a maximum of 20' of 4" O. D. fresh air intake pipe with two (2) 90° elbows, 25' with one (1) elbow, or 30' with no elbows. 3.
PAGE 15
INSTALLATION Figure 15.2 - Recommended Installation of Flexible Gas Connector 7. When pressure/leak testing pressures above 14" W.C. (1/2 psi), close the field installed shut-off valve, disconnect the unit, 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-off valve on the unit before testing. 8.
PAGE 16
INSTALLATION - HIGH ALTITUDE ACCESSORY KIT HIGH ALTITUDE ACCESSORY KIT Manifold Pressure Adjustment Modine’s gas-fired equipment standard input ratings are certified by ETL. For elevations above 2,000', ANSI Z223.1 requires ratings be reduced 4 percent for each 1000' above sea level. For units in Canada, CSA requires that ratings be reduced 10 percent at elevations above 2,000'.
PAGE 17
INSTALLATION - HIGH ALTITUDE ACCESSORY KIT Table 17.
PAGE 18
INSTALLATION/START-UP PROCEDURE Electrical Connections IMPORTANT WARNING Start-up and adjustment procedures should be performed by a qualified service agency. 1. D isconnect power supply before making wiring connections to prevent electrical shock and equipment damage. 2. All appliances must be wired strictly in accordance with wiring diagram furnished with the appliance. Any wiring different from the wiring diagram could result in a hazard to persons and property. 3.
PAGE 19
START-UP PROCEDURE Main Burner Adjustment The gas pressure regulator (integral to the combination gas control) is adjusted at the factory for average gas conditions. It is important that gas be supplied to the heater in accordance with the input rating on the serial plate. Actual input should be checked and necessary adjustments made after the heater is installed. Over-firing, a result of too high an input, reduces the life of the unit and increases maintenance.
PAGE 20
DIMENSIONAL DATA Figure 20.1 - Casing Dimensions (in.) TOP VIEW 10.00 23.12 BACK VIEW 12.39 ø 1.000 GAS CONNECTION SIDE VIEW FRONT VIEW 1.36 2.61 ø .875 THERMOSTAT CONNECTION ø .875 LINE VOLTAGE CONNECTION 14.99 13.58 3.65 4.00 4.00 6.00 21.91 11.00 6.00 12.00 Figure 20.2 - Burner and Tube System Dimensions (inches) A 14 11 B 16 28 Table 20.1 - Tube Systems Data Tube Length (ft.) 20 30 40 50 60 70 Straight Tube System Length “A” (ft.) System Weight (lb.
PAGE 21
PERFORMANCE Table 21.1 - Performance Input MBH 50 60 20, 30 Certified Tube Lengths (ft.) Recommended Mounting Height (ft.
PAGE 22
MAINTENANCE/SERVICE & TROUBLESHOOTING MAINTENANCE Removal of Ignitor and Flame Sensor Housing Burner Assembly Figure 22.2 - Ignitor and Flame Sensor Housing Qualified gas service personnel should service all heating equipment before each heating season to assure proper operation. The following items may require more frequent service based on the environment in which the unit is installed, and how long the unit is operated.
PAGE 23
TROUBLESHOOTING Table 23.1 - Troubleshooting TROUBLE POSSIBLE CAUSE POSSIBLE REMEDY Unit does nothing 1. Power supply is off 1. Turn on main power 2. No 24V power to thermostat 2 a. Check control transformer b. If failed transformer - check thermostat wire gage and length 3. Thermostat malfunction 3 a. Verify wire connections to R&W terminals only b. Check / replace thermostat 4. LED flashes 4. Check LED flash code 5. Blown fuse on control board 5. Replace fuse 6. Defective control 6.
PAGE 24
SERVICE & TROUBLESHOOTING/REPLACEMENT PARTS ORDERING Replacement Parts Ordering When servicing, repairing or replacing parts on these units, locate the model identification plate of the unit and always give the complete Model Number and Serial Number. The model identification plate is located inside the burner casing, and is shown in Figure 24.1. The part numbers for common replacement parts are also listed on a separate plate, shown in Figure 24.1.
PAGE 25
MODEL NUMBER / SERIAL NUMBER / WIRING DIAGRAM Figure 25.1 - Model Number Designations 1, 2, 3 DIGIT SEQUENCE 4, 5, 6 7 8, 9 10, 11 IPT 200 S 01 11 MODEL NUMBER CONTROL CODE: MODEL PREFIX: 11: SINGLE STAGE, NATURAL GAS 21: SINGLE STAGE, PROPANE GAS 12: TWO STAGE, NATURAL GAS 22: TWO STAGE, PROPANE GAS IMPROVED PRESSURE TUBE: IPT MODEL SIZE: MBH INPUT: 50, 60, 75,100, 125, 150, 175, 200 POWER CODE: IGNITION TYPE: S: DIRECT SPARK 01: 115V/60HZ/1PH Figure 25.
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Figure 26.
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COMMERCIAL WARRANTY Seller warrants its products to be free from defects in material and workmanship, EXCLUSIVE, HOWEVER, of failures attributable to the use of materials substituted under emergency conditions for materials normally employed.