Ambirad Vision VPLUS HL120V Instruction manual

Doc No 700105 (06-15), Page
VPLUS HL OWNERS MANUAL
INSTALLATION / OPERATION / MAINTENANCE
Applies to: Model VPLUS HL120V 60Hz
Gas-Fired, Tubular, Radiant,
Low-Intensity Infrared Heater
Part # 700105
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause
property damage, injury or death. Read the
installation, operating and maintenance instructions
thoroughly before installing or servicing this
Vision Range
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Doc No 700105 (06-15), Page 2
and servicing is undertaken on radiant tube
heaters specified in these instructions, due care
and attention is required to ensure that working
at height regulations are adhered to.
PLEASE READ this document prior to
installation to familiarize yourself with the
components and tools you require at the various
stages of assembly.
All dimensions shown are in inches unless
otherwise stated.
The manufacturer reserves the right to alter
specifications without prior notice.
Welcome to the new range of powered HiLo
infra-red heaters. Local regulations may vary
and it is the installer’s responsibility to ensure
that such regulations are satisfied.
All installation, assembly, commissioning and
service procedures must be carried out by
suitable qualified competent persons and
conform with local building codes, or in the
absence of local codes, with the National Fuel
Gas Code ANSI Z223.1/NFPA 54 or the
National Gas and Propane Installation Code
CSA B149.1.
When assembling, installing, commissioning
codes, with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas
and Propane Installation Code, CSA
B149.1.
D. The unit shall be electrically grounded in
accordance with National Electric Code
ANSI/NFPA 70 and Canadian Electrical
Code CSA C22.1.
E. The heater may be installed in aircraft
hangars in accordance with the Standard
for Aircraft Hangars, ANSI/NFPA 409 and
in automotive garages when installed in
1.1 Health and Safety
A. Heater is intended for heating
non-residential indoor spaces and should
only be installed where flammable gases
or vapors are not generally present.
B. Heaters may be suspended either
horizontal or at any angle. See section
1.3 for clearance dimensions.
C. The installation must conform with local
building codes or, in the absence of local
1 Installation Requirements
1.1 Health & Safety
1.2 Heater Suspension
1.3 Clearance to Combustibles
1.4 Gas Connection & Supply Details
1.5 Electrical Connections
1.6 Ventilation Requirements
1.6.1 Unvented Units
1.6.2 Vertical Venting
1.6.3 Horizontal Venting
1.7 Fresh Air Intake
1.8 Technical Details
2 Assembly Instructions
2.1 Tools Required
2.2 Assembly Notes
2.2.1 Tubes
2.2.2 Turbulator Strips and Burner Inserts
2.2.3 Brackets
2.2.4 Couplers
2.2.5 Reflectors
2.2.6 End Caps (optional)
2.2.7 Bends (where required)
2.2.8 Burner/Fan Assembly
2.2.9 Detailed Assembly Drawings
3 Start Up Instructions
3.1 Tools Required
3.2 Start up procedure
4 Servicing Instructions
4.1 Tools Required
4.2 Burner Description
4.3 Burner Removal
4.4 Burner Gas Injector Servicing
4.5 Burner Head and Electrode Servicing
4.6 Combustion Fan Assembly
4.7 Radiant Tube Servicing
4.8 Reflector Servicing
4.9 Cleaning of Vent
4.10 Re-commissioning after Service
5 Troubleshooting Guide
6 Replacing Parts
6.1 Burner Controller Replacement
6.2 Air Pressure Switch Replacement
6.3 Gas Valve Replacement
7 User and Operating Instructions
7.1 To Start Heater
7.2 To Switch Off Heater
7.3 Servicing
Introduction.
Document Index.
1. Installation Requirements.
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Doc No 700105 (06-15), Page 3
accordance with the Standard for
Parking Structures, ANSI/NFPA 88A, or
the Standard for Repair Garages, ANSI/
NFPA 88B, or the Canadian Natural Gas
and Propane Installation Code, CSA
B149.1, and are so marked.
Ensure that minimum clearances will be
maintained to vehicles parked below the
heater.
F The standard heaters are approved for
installations between 0 - 2000ft (0 - 610m)
for the US and 0 - 4500 ft (1370m) for
Canada. Conversion kits are available on
installations above these heights in the
USA.
G. Massachusetts Requirement: If the
heater is being installed in the
Commonwealth of Massachusetts, this unit
must be installed by a licensed plumber or
licenced gas fitter.
1.2 Heater Suspension
Attachment to the heater support lugs should
be made by D shackle. The hanging
attachments to overhead steelwork etc. must
be purpose made to sound engineering practice
or supplied by others. They must be adequately
fixed and designed to carry the whole weight of
the heater. In the event of suitable roof
steelwork being unavailable, additional
steelwork should be fitted to enable vertical
hangers to be used for suspending the heaters.
These methods are illustrated in Figure 1. If
there are any doubts as to the strength or
suitability of roof steelwork to which heaters are
to be suspended, please refer to a Consultant,
Architect or owner of the building.
It is recommended that the heater is raised to its
final position once the assembly of the tube/
bracket/reflector has been completed. Longer
tube assemblies may be raised in more than
one sub-assembly with final tube connection
made in the air.
Ensure that the installer uses the burner roof
support mounting bracket when suspending the
heater. This is situated on the front of the
burner. When packed the bracket is reversed
and must be turned to its correct state for
mounting. (ref page 18)
WARNING:
If not installed, operated and maintained in accordance with the manufacturer’s
instructions, this product could expose you to substances in fuel or from fuel combustion
which are known to the state of California to cause cancer, birth defects or other
reproductive harm.
CHAIN 55° SUSPENSION
NOTE.
'S' HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
EXHAUST
END
BURNER
END
U TUBE VARIANTS
SUITABLE CHAIN
WORKING LOAD
LIMIT 100LB
Figure 1. Recommended Methods of Heater Suspension.
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Doc No 700105 (06-15), Page 4
1/2
”
UNVENTED
VENTED
1/2”
1.3 Clearance to Combustibles.
Minimum clearance to combustibles are shown in Table 1 below.
IMPORTANT:
The stated clearance to combustibles represents a surface temperature of 90°F (50°C) above room
temperature. Building material with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply,
etc.) may be subject to degradation at lower temperatures. It is the installer’s responsibility to assure
that adjacent materials are protected from degradation.
Building material with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.) may be
subject to degradation at lower temperatures.
It is the installer’s responsibility to assure that adjacent materials are protected from degradation.
Table 1 Clearance to Combustibles, inches (cm)
MODEL A A1 / A2 B B1 C1 C2 C3 D1 D2 E
40 49
(125)
15° = 48 (122)
25° = 45 (115)
35° = 41 (105)
45° = 35 (89)
55° = 29 (74)
24
(61)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
60 74
(188)
29
(74)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
80 74
(188)
29
(74)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
100 74
(188)
32
(82)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
16
(41)
12
(31)
125 74
(188)
39
(99)
47
(120)
20 (51) /
10* (26)*
8
(21)
22
(56)
20
(51)
18
(46)
12
(31)
150 74
(188)
39
(99)
48
(122)
20 (51) /
10* (26)*
8
(21)
22
(56)
20
(51)
18
(46)
12
(31)
170 86
(219)
15° = 82 (209)
25° = 78 (199)
35° = 71 (181)
45° = 61 (155)
55° = 50 (127)
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(31)
200 86
(219)
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(31)
15° = 72 (183)
25° = 68 (173)
35° = 61 (155)
45° = 53 (135)
55° = 43 (110)
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be
maintained. Signs should be posted in storage areas to specify maximum stacking height to
maintain required clearance to combustibles. Such signs must either be posted adjacent to
the heater thermostats or in the absence of such thermostats in a conspicuous location.
Refer to mounting clearance tables.
WARNING:
* distance with end caps fitted.
ON VENTED HEATERS, THE HEATER SHOULD SLOPE DOWNWARDS AWAY FROM
THE BURNER AND ON UNVENTED HEATERS SHOULD SLOPE DOWNWARDS
TOWARDS BURNER BY APPROX. ½” FOR HORIZONTAL INSTALLATIONS AS SHOWN
BELOW (DIAGRAMS EXAGGERATED FOR CLARITY)
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Doc No 700105 (06-15), Page 5
C2
C1
A
B1
B
B
A1
E
D2
.
D1
Ensure that there is adequate
provision in the building for
combustion and ventilation air supply.
Installation must meet minimum
requirements and applicable codes.
Burner end.
Outlet end. Angled view.
End view.
C3
Below
heater
Side
vented
Side
unvented
End
unvented
Above outlet
unvented
Above
Reflector
Above
Burner
Service
distance
Return end on
U tube heater
WARNING!
0° to 55°
A2
C1
E
Above
Burner
Service
distance
Figure 2 Clearance to Combustibles (Standard indoor reflectors)..
The minimum clearances to combustible materials are given in Table 1 These minimum
distances MUST be adhered to at all times. Adequate clearance MUST be provided around air
openings into the combustion chamber and there MUST be suitable clearance for accessibility and
for combustion / ventilating air supplies.
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Doc No 700105 (06-15), Page 6
1.4 Gas Connection and Supply
The gas connection on the heater is ½” N.P.T
internal thread.
Injector sizes and manifold pressure for the
burners are shown in the table 3. The gas
supply piping and connections must be installed
so that the minimum pressure stated is
achieved.
A gas shut off valve and union should be fitted
in the gas supply line close to the heater and a
⅛” N.P.T plugged tapping, accessible for test
gauge connection, provided immediately
upstream of the appliance gas inlet.
It is essential to provide some flexibility in the
final gas connection by use of an approved
flexible gas connector. (See Fig 4.)
Take care when making a gas connection
to the heater not to apply excessive turning
force to the internal controls.
Care must be taken to observe the minimum
pipe bend diameter (minimum 10” (254mm),
maximum 14”(356mm) & pipe expansion
distance (minimum 1⅛” (25.4mm), maximum
3¾”(95mm).
The correct installation as shown will allow
for approx 4” of movement due to
expansion.
WARNING: Before installation, check
that the local distribution conditions,
nature of gas and pressure, and adjustment
of the appliance are compatible.
Figure 3. Correct orientation of Ball Valve
Gas Flow
Gas Flow
Figure 4. Correct Installation of Flexible
Gas Connection
Table 2 HOSE SIZE PART No.
3/4” A4129
1/2” A4128
* Connector must be certified for use on a radiant tube
type infrared heater and must comply with Standard for
Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 or
with the Standard for Elastomeric Composite Hose and
Hose Couplings for Conducting Propane and Natural Gas,
CAN/CGA 8.1.
For heaters up to 150,000Btu/h, ½” ID x 24” long
For heaters 150,000Btu/h and above, ¾” ID x 36” long
NOTE: For Canada all heaters MUST use a hose 36” long
(See Table 3)
WARNING: FIRE OR EXPLOSION HAZARD - It is essential to provide some flexibility in
the final gas line connection by use of an approved flexible connector as shown in the
drawings. Expansion of the radiant pipe occurs with each firing cycle causing the burner to
move with respect to the gas line. This can result in a gas leak producing an unsafe
condition.
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Doc No 700105 (06-15), Page 7
Table 3 Gas Supply Pressures
Gas Type Natural Gas LP/Propane Gas
Min Required Gas Pressure (in W.C) 7.0 11.0
Max Supply Pressure (in W.C) 14.0 14.0
Gas Supply Connection ½” N.P.T thread
CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. FOR HEATERS UP
TO 150,000 BTU/H, A 24” LONG CONNECTOR OF AT LEAST ½” ID MUST BE USED.
FOR HEATERS ABOVE 150,000 BTU/H, A 36” LONG CONNECTOR OF AT LEAST ¾”
NOMINAL ID MUST BE USED.
F2
F1
R
C
W1
W2
24V AC
Terminals
(120V AC Fan
Terminals)
120V AC
Supply
24V AC 2-Stage
Thermostat (Ext.)
RC
W1 W2
Burner 1
E
N
L
N
E
BL
BK
KEY:
BK-BLACK
BL-BLUE
R-RED
O-ORANGE
G-GREEN
W-WHITE
R
O
BK
G
W
Notes:
Use 18/4 class 2 thermostat cable
between heater and thermostat.
Max. length @ 18 Awg (0.8mm²) =
100ft.
Only one burner can operate from
one thermostat as supplied.
When servicing heaters ensure
the electricity supply is isolated
from the mains supply.
120V AC supply is still present at
each burner when the thermostat
is switched off.
1.5 Electrical Connections
This appliance must be electrically grounded
Supply 120V 60Hz single phase.
Standard heater 0.16HP.
Current rating (inductive):
1.8 amp max (models 40 - 150)
1.0 amp max (models 170 & 200)
Fuse: external 3 amp.
Important: All electrical work should be done by a
qualified electrician in strict accordance with the
National Electrical Code ANSI/NFPA 70 or
Canadian Codes CSA C22.1.
The electrical supply to
the heater is by three
wires: hot (Live), neutral
and ground connections.
Install in accordance with
all state & local codes.
Where alternative
manufacturers controls
are used, please refer to
their instructions for their
installation details.
WARNING: Before making electrical
connections, switch OFF the main
electrical disconnect. There may be more
than one disconnect switch. Lock out
and tag switch with a suitable warning
label. Electrical shock can cause
personal injury or death.
Figure 5. External Wiring Schematic
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Doc No 700105 (06-15), Page 8
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
with wiring material having a temperature rating of at least 220°F/105°C
LN
E
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
E
Gas Valve
C
M
HI
NOTES:-
Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner.
Additional wiring is required to install an optional extra thermostat and / or time clock.
Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C
Pressure Switch
120V/24VAC 60Hz
Transformer
Power ON (red)
BK
R
Y
O
BR
GR
BL
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
R - RED
W - WHITE
Y - YELLOW
O - ORANGE
P - PURPLE
BR
Y
P
YY
R
W
G
BK
W
G
BL BR
PGR
P
GR
K
BR
W
BK
LNE
120V AC
Supply
BK
F1 NEF2
120V AC Fan
Terminals
High Fire
KGR
24V AC
RELAY
21
1424
11
A2
1222
A1
High Fire
Relay
COIL
NC
NO
COM
CW2W1 R
24V AC Stat
Terminals
K
O
BL
BR
Low Fire
(amber)
CW2W1 R
24V Two stage
Thermostat
R
W
G
BK
W
G
BK
BL
R
BK
R
K
O
BL
BR
E
Figure 6a. Internal Burner Wiring Diagram.
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Doc No 700105 (06-15), Page 9
1.5.1 Multiple burner configurations (Master
& Slave) via Optional Relay.
Refer to figure 6b and 6d.
Multiple burners can be controlled via one main
burner. In this scenario the main burner is
knows as the ‘Master’ and any additional
burners are known as ‘Slaves’.
The external two stage thermostat is connected
to the Master burner and powered via the inbuilt
transformer. The total burner load for the Master
is 20VA. Each additional ‘Slave’ burner is 1.6VA
The Thermostat chosen to control the multiple
heaters must not have a power requirement
exceeding the spare capacity as shown in the
examples below.
CONFIGURATION TOTAL BURNER LOAD SPARE FOR THERMOSTAT
Master PLUS 1 Slave 21.6VA 18.4VA
Master PLUS 3 Slaves 24.8VA 15.2VA
Master PLUS 5 Slaves 28.0VA 12.0VA
Master PLUS 7 Slaves 31.3VA 8.8VA
Figure 6b. Wiring schematic. Multiple Burners Master and Slave.
Figure 6c. Wiring schematic. Multiple Burners via independently powered Relay.
Supply circuit
120V 60Hz 1 Ph
L2
L1 (HOT)
GND
MASTER
BURNER
THERMOSTAT
SLAVE
BURNER
SLAVE
BURNER
SLAVE
BURNER
LEN
R
C
W1
W2 W1 W2 W1 W2 W1 W2
LENLENLEN
R
C
W1
W2
24VAC 60Hz 1 Ph Hi/Lo circuit
1.5.2 Multiple burner configuration via
independently powered two stage
thermostats. Refer to figures 6c and 6d.
Note: If the thermostat has an independent
power supply, all burners in the zone to be
controlled MUST be Slave burners.
The maximum number of Slave burners per
thermostat is dependent on the maximum
power output of the thermostat selected.
Each ‘Slave’ burner is rated at 1.6VA 24VAC
60Hz.
The external two stage thermostat is powered
via its own power supply and must output to
each Slave burner - 24VAC for low fire to
terminal W1 and 24VAC for hi fire to both
terminals W1 and W2
Refer to thermostat manufactures literature for
details.
Supply Circuit
(by others)
Supply circuit
120V 60Hz 1 Ph
L2
L1 (HOT)
GND
SLAVE
BURNER
THERMOSTAT
SLAVE
BURNER
SLAVE
BURNER
SLAVE
BURNER
LEN
W1
W2
W1 W2 W1 W2 W1 W2
LENLENLEN
Low fire output
Hi fire output
24VAC 60Hz 1 Ph Hi/Lo circuit
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Doc No 700105 (06-15), Page 10
E
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
E
Gas Valve
C
M
HI
NOTES:-
Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner.
Additional wiring is required to install an optional extra thermostat and / or time clock.
Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C
Pressure Switch
120V/24VAC 60Hz
Transformer
BK
R
Y
O
BR
GR
BL
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
R - RED
W - WHITE
Y - YELLOW
O - ORANGE
P - PURPLE
BR
Y
P
YY
R
W
G
BK
W
G
P
GR
K
BR
W
BK
LNE
120V AC
Supply
BK
F1 NEF2
120V AC Fan
Terminals
24V AC
RELAY
21
1424
11
A2
1222
A1
High Fire
Relay
COIL
NC
NO
COM
CW2W1 R
24V AC Stat
Terminals
K
CW2W1 R
24V Two stage
Thermostat
R
W
G
BK
W
G
BK
BL
R
BK
R
K
O
E
BL
24V AC
RELAY
21
1424
11
A2
1222
A1
COIL
NO
BL
O
COM
O
BL
BR
R
OPTIONAL RELAY WIRING
Relay mini harness leads
5A connector
BR
LN
Power ON (red)
BL BR
PGR
High Fire
KGR
Low Fire
(amber)
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
with wiring material having a temperature rating of at least 220°F/105°C
Figure 6d. Internal Slave Burner Wiring/External Schematic Diagram with Optional Relay.
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Doc No 700105 (06-15), Page 11
1.6 Vent Requirements and Details
1.6.1 Unvented units
Heaters may be installed unvented providing
the governing building codes are met and
consideration is properly given to
possibilities of condensation on cold surfaces.
Installation shall meet the following
requirements when unvented:
• Natural or mechanical means shall be
provided to supply and exhaust at least 4
CFM per 1000 BTU per hour input of
installed heaters.
• Combustion gasses shall not impinge on
combustible materials.
1.6.2 Vertical venting
The heater can be installed with a vertical vent.
All vent piping should be adequately supported
from the building structure and terminated with
an approved terminal. The maximum
recommended vent length is 25ft (7.6m) with
a maximum of two elbows. All connections
should be properly sealed. refer fig 7a
1.6.3 Horizontal venting
Individual units can be vented horizontally
through side walls.
Distances from adjacent public walkways,
adjacent buildings, openable windows and
building openings, consistent with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54 or the
Natural Gas and Propane Installation Code,
CSA B149.1.
Maximum length of vent is 25ft (7.6m) with two
- 90° elbows.
Runs of 12ft (3.6m) or shorter can use
4” (101mm) dia. vent. Runs over 12ft (3.6m)
should use 6” (152mm) vent pipe.
An approved clearance thimble is required
when the flue pipe passes through combustible
materials. Follow the requirements of the
thimble and/or vent pipe manufacturer.
Standard vent terminals must extend at least
6” (152mm) from the wall and at least
24” (609mm) from any combustible overhang.
This protects the building material from
degradation by the vent gasses.
Vent joints should be sealed and secured
according to the vent manufacturers
instructions. Should condensation occur the
vent should be shortened or insulated.
The terminal should be at least 3ft (0.91m) from
any air intake to the building.
The vent terminal must be installed at a suitable
height above the ground to prevent blockage by
snow.
1.7 Fresh Air Intake
Whenever the heater is installed in locations
where airborne dust or other pollutants are
present, a fresh air supply should be ducted to
the burner.
If the heater is equipped with ducted combustion
air, the vent terminal must be at least 3ft
(0.91m) away from the air inlet and located
higher than the inlet.
A fresh air duct of 4” (101mm) dia. should be
installed from the fresh air to the air intake
connection on the fan housing. A flexible
jointing piece should be installed at the fan
connection with hose clamps to facilitate
expansion and contraction.
The maximum recommended length air duct is
25ft (7.6m) and the maximum number of elbows
is two. The minimum length is 18” (456mm).
The location of the fresh air duct inlet must be
where it will receive dust free clean air. An inlet
cap with bird screen must be fitted at the inlet of
the duct. If the duct inlet is located above the
roof the underside of the inlet terminal must be
at least 2ft (0.61m) above roof level (or above
projected snow load) and at least 10” (254mm)
above any projection on the roof within 7ft
(2.1m) of the inlet. Intake pipe, fittings and
sealant are not furnished by the manufacturer.
Refer fig 7c & d.
Note the vent terminal must NOT be installed
below the fresh air intake, and should have a
minimum separation distance of 36” from the air
intake.
Note The vent terminal should be installed so as
to be in the same atmospheric pressure zone as
the combustion air inlet of the appliance.
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Doc No 700105 (06-15), Page 12
Aluminum 4” (101mm) O.D. pipe.
Max length = 25’0” (7.62M) with 2
x 90° long radius bends.
4” (101mm) O.D. flexible duct
Burner
Clamps
Figure 7.c Fresh Air Ducted Intake.
Note The vent terminal
should be installed so as
to be in the same atmospheric
pressure zone as the combustion
air inlet of the appliance.
Note the vent terminal must NOT
be installed below the fresh air
intake, and should have a
minimum separation distance of
36” from the air intake.
Approved clearance thimble is required when the flue pipe
extends through combustible materials. Follow the
requirements of the thimble and/or Category III vent pipe
manufacturer.
Approved Vent Cap
Figure 7.b Horizontal Venting (plan view shown).
Approved Vent Cap
Figure 7.a Vertical Venting.
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Doc No 700105 (06-15), Page 13
1.8 Technical Details - Table 5
No of Injectors 1
Gas Connection ½” N.P.T
Electrical Supply 120 volt 1 phase 60Hz
Vent size (in) 4” or 6” (101mm or 152mm)
Unitary Fan Motor Details 120 volt 1 phase 60Hz
Current Rating 1.8A MAX (models 40 - 150); 1.0A MAX (models 170 & 200)
Ignition Electronic Program Start up with Spark Ignition
MODEL Natural Gas LP Gas Min. Heater
Length Max. Heater
Length
Min. Heater
Length Max. Heater Length
High / Low
Rate BTU/Hr High / Low Rate BTU/Hr S ft S ft U ft U ft
60 60,000/48,000 60,000/48,000 20 40 20 40
80 80,000/60,000 80,000/60,000 30 40 40 40
100 100,000/75,000 100,000/75,000 30 40 40 40
125 123,500/95,000 125,000/95,000 30 50 40 40
150 150,000/100,000 150,000/100,000 40 60 40 60
170 169,000/125,000 169,000/125,000 50 70 60 60
200 200,000/160,000 N/A 50 70 60 60
40 41,500/31,125 41,500/31,125 10 20 20 20
Appliances can be installed up to 10,000ft in the USA. Altitude conversion kits are available on request.
USA 0- 2000 ft (0-610m)
Size 60 80 100 125 150 170 200
Gas
Hi “WC 3.9 3.5 4.5 4.3 4.0 3.3 4.0
Lo “WC 2.6 2.3 3.0 2.7 2.1 1.9 2.5
Natural Gas
40
3.1
2.1
CANADA 0- 2000 ft (0-610m)
Size 60 80 100 125 150 170 200
Gas
Hi “WC 3.9 3.5 4.5 4.3 4.0 3.3 4.0
Lo “WC 2.6 2.3 3.0 2.7 2.1 1.9 2.5
Natural Gas
40
3.1
2.1
USA 0- 2000 ft (0-610m)
Size 60 80 100 125 150 170 200
Gas
Hi “WC 5.5 5.2 8.0 7.6 7.0 6.1 N/A
Lo “WC 3.5 2.9 4.4 4.6 3.3 3.6 N/A
LP Gas
40
3.4
2.3
CANADA 0- 2000 ft (0-610m)
Size 60 80 100 125 150 170 200
Gas
Hi “WC 5.5 5.2 8.0 7.6 7.0 6.1 N/A
Lo “WC 3.5 2.9 4.4 4.6 3.3 3.6 N/A
LP Gas
40
3.4
2.3
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Doc No 700105 (06-15), Page 14
MODEL U Tube Straight Tube
U20 U40 U60 S20 S30 S40 S50 S60 S70
60 ●●●●●
80 ●●●
100 ●●●
125 ●●●●
150 ●●●●●
170 ●●●●
200* ●●●●
S10
40 ●●●
MODEL Tube Type Material Min. Distance to Bend
ft (m)
Calcoat™ Mild Steel
60 TUBE 1 REMAINDER 10 (3.0)
80 TUBE 1 REMAINDER 10 (3.0)
100 TUBE 1 REMAINDER 15 (4.6)
125 TUBE 1 REMAINDER 15 (4.6)
150 TUBE 1 REMAINDER 20 (6.1)
170 TUBE 1 & 2 REMAINDER 25 (7.6)
200 TUBE 1 & 2 REMAINDER 25 (7.6)
40 TUBE 1 REMAINDER 10 (3.0)
Technical Details continued
* Nat Gas ONLY
USA & CANADA Natural Gas 0- 2000 ft (0-610m)
Size 40 60 80 100 125 150 170 200
Burner Orifice Plate Part No. 201063-57 201063-77 201063-67 201063-23 201063-26 201063-78 201063-24
Flame Plate Part No. N/A
Fan Part No. 201957 202132
Fan Orifice Part No. 202483 201654 L200301 201425 L200244 202133 201911
Injector Part No. 201007-13 201007-15 201007-18 201007-19 201007-23 201007-29 201631-28 201631-32
Injector Carrier Part No. 202262
Pressure Switch Part No. 201508 201676 201697
202261
USA & CANADA LP Gas 0- 2000 ft (0-610m)
Size 40 60 80 100 125 150 170 200
Burner Orifice Plate Part No. 201063-75 201063-74 201063-72 201063-56 201063-55 201063-54 201063-68
N/A
Flame Plate Part No. 201571 201358 201571 201854 201905
Fan Part No. 201957 202132
Fan Orifice Part No. 202483 202253 L200301 L200264 L200244 L200246 202352
Injector Part No. 201007-10 201007-11 201007-13 201007-15 201007-17 201007-19
Injector Carrier Part No.
Pressure Switch Part No. 201508 201676
202261
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Doc No 700105 (06-15), Page 15
2. Assembly Instructions.
2.2.2 Turbulator Strips and Burner
Inserts
Ensure that the correct turbulator or burner
insert is fitted, as this could void your warranty if
they are incorrectly fitted or omitted when
necessary.
2.2.2.1 Turbulator Strips
Turbulator strips should be inserted (when
required) into the correct tube exactly as
indicated in the assembly drawings.
Locate turbulator strip sections. Install the first
turbulator strip into the open end of the last tube
(only after it has been suspended and
connected to the previous tube.)
Interlock the next section of turbulator strip as
shown in the diagram below.
2.2 Assembly Notes.
2.2.1 Tubes
Each heating unit has two types of emitter tube.
For details of the tube types and position
please refer to the table (page 14 of this
instruction manual).
Identify and position tubes on saw horses. For
aesthetics it is advisable to position all tube
seams facing down. Position coupling
fastener so that these cannot be seen from
beneath the heater.
Mark out the position of the bracket centers
from the dimensions shown on the assembly
drawings.
PLEASE READ this section prior to
assembly to familiarize yourself with the
components and tools you require at the
various stages of assembly. Carefully open the
packaging and check the contents against the
parts and check list.
The manufacturer reserves the right to alter
specifications without prior notice.
Please ensure that all packaging is
disposed of in a safe environmentally
friendly way.
For your own safety we recommend the
use of safety boots and leather faced
gloves when handling sharp or heavy items. The
use of protective eye wear is also
recommended.
Phillips
Screwdriver
Saw
Horses
Leather
Faced
Gloves
Tape
Measure
5/16”
Drive
Cordless
Drill
Wrench
Set
2.1 Tools Required.
The following tools and equipment are advisable
to complete the tasks laid out in this manual.
Suitable alternative tools may be used.
Please read these assembly notes in
conjunction with the correct assembly
drawings (figs 9 to 18).
3/16” (5mm)
5/32” (4mm)
Allen
wrench
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Doc No 700105 (06-15), Page 16
Fit three turbulator strips here
Vent Vent
Fit the remaining turbulator strips here
Slide the connected sections into the tube(s).
Add further strips to form the correct length
required.
2.2.2.2
Where a heater configuration requires more
than three turbulator strips and has the exhaust
heat exchanger tube adjacent to an “L” or “U”
heat exchanger tube, refer to the diagram below
for positions.
For specific configurations see detailed
assembly diagrams on pages 22 to 31.
2.2.2.2 Burner Inserts
The burner insert (when required) is inserted
into the first heat exchanger tube from where it
is joined to the second tube.
2.2.3 Brackets
There can be various styles of brackets
supplied with these heaters:
2.2.3.1 Suspension Brackets
2.2.3.1.1 Fixed suspension bracket assembly
part #L201020 & tube straps part #L201021-
SUB ONLY used as the first suspension bracket
positioned CLOSEST TO THE BURNER.
Slip the suspension first bracket assembly - part
#L201020 onto the first section of tube in the
position as indicated on the assembly drawing.
Locate the tube strap assembly part #L201021-
SUB and loosen the nut and bolt.
Position the strap over the tube and hook the
two straps onto the suspension bracket.
Finally tighten the nut and bolt to secure the
bracket onto the emitter tube.
2.2.3.1.2 Suspension brackets #L201020 with
no tube straps. For ALL other suspension
brackets
Once the emitter tubes have been assembled
using the couplers (see section 2.2.4), position
all other suspension brackets part #L201020
onto the tube(s) in their relevant positions as
shown on the assembly drawing.
PARTS #L201020 plus #L201021-SUB
TUBE
STRAP
RADIANT
TUBE
SUPPLIED
NUT & BOLT
SUSPENSION
BRACKET
"A"
VIEW ON "A"
PART #L201020
RADIANT
TUBE
SUSPENSION
BRACKET
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Doc No 700105 (06-15), Page 17
Moving between the two screws, tighten each
one in turn ensuring that equal pressure is
applied to both. Complete assembly by drilling
and screwing self tapping retention zip screws.
A standard stainless steel 4” coupling which is
used for all other fixings.
Slide the coupler over the tube ensuring that the
rivet stop has butted up to the tube ends. Using
the 5/16” drive, tighten the bolts.
DO NOT OVERTIGHTEN!!
Moving between the two tightening bolts, tighten
both ensuring that equal pressure is applied to
each in turn. Complete assembly by drilling and
screwing self tapping retention zip screws.
2.2.3.2 Reflector Support Brackets
Reflectors are positioned above the emitter
tube with a reflector support bracket part
#L201008-SUB
Locate a suspension support bracket and
remove the bolt fixing the strap to the bracket.
Position the bracket over the emitter tube and
loosely replace the bolt.
Roughly position the support brackets in place
along the tube assembly as indicated on the
assembly drawing. The positioning may need to
be adjusted when the reflector is added.
2.2.4 Couplers
There are two types of couplers for joining
radiant tubes and U or L bends.
A high temperature stainless steel 4” coupling
which is used as detailed in the following table.
Slide the coupler over the tube ensuring that
the rivet stop has butted up to the tube ends.
Using the Allen wrench, tighten the pins.
DO NOT OVERTIGHTEN!!
Model First coupler Second coupler
40-100 Standard Standard
125-150 Hi-temp Standard
170-200 Hi-temp Hi-temp
STAINLESS
STEEL
SPACER
SELF TAPPING ZIP
SCREWS
DRAW BAND COUPLING
BOLTS
Self Tapping
Zip Screws
Draw Band Coupling
Bolts
Stainless
Steel
Spacer
At this point raise the tube assembly into
position and suspend from previously fixed
chains (Working Load 100lb). Longer tube
assemblies may be raised in more than one
sub-assembly with final tube connection made
in the air.
REFLECTOR BRACKET #L201008-SUB
TUBE
STRAP
RADIANT
TUBE SUPPLIED
NUT &
BOLT
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Doc No 700105 (06-15), Page 18
These overlapped reflectors are allowed to
‘float’ within the support bracket by leaving a
minimum of 1/8” gap of the fixing screws before
tightening the locknuts.
These are known as ‘slip’ overlaps.
Further reflectors are assembled and
overlapped onto the emitter tube by alternating
‘non-slip’ and ‘slip’ until complete length is
covered.
Continue this method to the final reflector/
support bracket.
2.2.6 End Caps
Position an end cap beneath the reflector
profile (where required) with the end cap
flanges facing inwards. Fasten to reflector
using the four ’Z’ clips.
2.2.5 Reflectors.
After removing the coloured protective plastic
coating (where fitted), slip the reflectors through
the suspension brackets until they overlap each
other.
The first two reflectors are assembled and
overlapped by a pre determined distance, as
shown on the assembly drawing, and are fixed
onto the emitter tube using the reflector support
bracket part #L201008-SUB .
Reposition the reflector support bracket if
necessary then tighten the clamp bolt.
These two reflectors are fixed in place by
tightening the fixing screws/locknuts as below.
These are known as ‘non-slip’ overlaps.
The next reflector is assembled and overlapped
by the pre determined distance. The reflector is
fitted onto the emitter tube using another
reflector support bracket part #L201008-SUB.
Reposition the reflector support bracket if
necessary, then tighten the clamp bolt.
All reflectors must be positioned/
attached to the brackets exactly as
detailed in the assembly drawings.
Each reflector must OVERLAP the
previous one as indicated by their
individual assembly sheets.
TIGHTEN SCREWS
TO FIX REFLECTOR
LEAVE 1
8" MIN GAP TO
ALLOW REFLECTOR TO SLIDE
1
8" min
End Cap
Stetch for typical ‘slip’ and ‘non-slip’ reflectors
Burner
Reflectors. Note: each reflector must overlap the previous one
Suspension Bracket
part #L201020
and fixing #L201021-SUB
Support Bracket
part #L201008-SUB
non-slip overlap
Support Bracket
part #L201008-SUB
slip overlap
Support Bracket
part #L201008-SUB
non-slip overlap
Further reflectors to be
overlapped in the same method
Subsequent support brackets to
be alternating 'slip' and 'non-slip'
2/0 GA CHAIN
(TWISTED LINK, PLATED)
NOTE.
HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
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Doc No 700105 (06-15), Page 19
Connect Gas and Electrical supplies as
described in sections 1.4 and 1.5.
2.2.8.1 Model 40 S10 fan orifice plate
This model has a different fan orifice plate (Part
No.202383) to all other models in the range. It is
supplied with every burner as a loose item and
should be discarded if not needed. This must
be fitted to the 40 S10 model only.
Note: There should be 25 5mm x 5mm square
holes in the replacement plate.
Remove the top cover of the burner to expose
the combustion fan.
Remove the four screws (arrowed), two of
which can not be seen in the photograph. Lift
out the fan assembly to access the fan.
Remove the three fixing nuts securing the
existing orifice plate, then fit the replacement
orifice plate with the correct air inlet hole
orientation as shown below.
Note: For high wind applications use
additional drill screws to secure end cap to the
reflector
2.2.7 Bend(s) (where fitted)
The heater can be installed with 1 or 2 90°
bends or a 180° U bend.
Slide the bend into the open end of the
coupler ensuring that the screw stop has butted
up to the tube ends. Refer to 2.2.4 for
fastening.
Typical usage of optional bend kit
2.2.8 Burner/Fan Assembly.
Slide the burner assembly onto the open tube
end, ensuring it is fully engaged. Secure with
set screws.
For the purpose of unvented applications, a 4”
90° elbow should be used on the terminating
end of the radiant tube sections. This elbow
should be turned with the outlet facing either
side.
90° Bend
End Caps
Corner reflector 90° Elbow
End Caps
16” crs
15”
U Bend
Corner reflector kit
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Doc No 700105 (06-15), Page 20
2.2.8.1 Model 200 S50 fan orifice plate
This model has a different fan orifice plate (Part
No.202254) to all other models in the range. It
is supplied with every burner as a loose item
and should be discarded if not needed. This
must be fitted to the 200 S50 model only.
Note: There should be 22 10mm x 10mm
square holes in the replacement plate.
Remove the top cover of the burner to expose
the combustion fan.
Remove the four screws (arrowed), three of
which can not be seen in the photograph. Lift
out the fan assembly to access the fan.
Remove the four fixing screws securing the
existing orifice plate, then fit the replacement
orifice plate with the correct air inlet hole
orientation as shown below.
2.2.9 Heater Configurations
The sketches shown on the following page
show various heater configurations for the
model series dependent on heater length and
rating. It is important not to configure a heater
outside of these recommendations.
2.2.10 Detailed Assembly Drawings
The following pages show the technical
dimensional details of the range of heaters.
Please note the heater type, length and
reference number from the delivery/advice note
before identifying the correct model drawing.
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