Detroit Radiant Products HL2 Series User manual

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HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual*
Printed in U.S.A.
©2002 Detroit Radiant Products Co.
21400 Hoover Rd., Warren, MI 48089
T. [phone] F. [phone]
Form#LIOHL2-3M-10/03(ID)
Replaces Form# LIOHL2-3M-12/02
HL2 Series
WARNING: This heater must be installed and serviced by trained gas installation and service personnel only!
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
Readtheinstallation,operatingandmaintenanceinstructionsthoroughlybeforeinstallingorservicingthisequipment.
Protect yourself and others by observing all safety information. Retain instructions for future reference.
!
* Model requires 5EA-SUB accessory package.
Table of Contents
Page
Models 1
Warnings 2
Clearancesto Combustibles 2
ProductSummary 3
ProductInstructions 3
HeaterRequirements 4
TheoryofOperation 4
WiringDiagrams 5-7
Flowchart 8-9
Parts Listing 10-11
Project: _________________________ Date: _______________
CustomerName: _______________________________________
Location: _____________________________________________
City: ______________________ State: _______ Zip: __________
Contractor:____________________________________________
Engineer: _____________________________________________
Address: _____________________________________________
City: ______________________ State: _______ Zip: _________
Serial #: _________________________Phone#: _____________
LocalRepresentative: ___________________________________
Dateof Installation:______________________________________
Notes: _______________________________________________
Models V.6/03
*For complete installation instructions, see the General Manual that accompanied this piece.
Additional literature on this and other products are available at www.reverberray.com.
Qty. Model # Gas Type
(circle one) MBTU's Straight
Length U-Tube Length Weight
Typical
Mount
Height Combustion Chamber Radiant Emitter Tube "Type" Tube Pkg #1 "Type" Tube Pkg. #2 Baffle Pieces
HL2 20-65 N or LP 65 / 50 21'-7' 13'-0" 120 # 9'-14' Aluminized 4" Aluminized 20-4 Alum N/A 5
HL2 20-75 N or LP 75 / 50 21'-7' 13'-0" 120 # 10' - 15' Aluminized 4" Aluminized 20-4 Alum N/A 5
HL2 20-100 N or LP 96 / 65 21'-7' 13'-0" 120 # 11' - 18' Aluminized 4" Aluminized 20-4 Alum N/A 5
HL2 30-65 N or LP 65 / 50 31'-3' *17'-8" 160 # 10' - 15' Aluminized 4" Aluminized 30-4 Alum N/A 4
HL2 30-75 N or LP 75 / 50 31'-3' *17'-8" 160 # 11' - 18' Aluminized 4" Aluminized 30-4 Alum N/A 4
HL2 30-100 N or LP 100 / 65 31'-3' *17'-8" 160 # 12' - 20' Aluminized 4" Aluminized 30-4 Alum N/A 5
HL2 30-125 N or LP 125 / 95 31'-3' *17'-8" 160 # 13' - 23' Aluminized 4" Aluminized 30-4 Alum N/A 5
HL2 40-65 N or LP 65 / 50 40'-11' 22'-8" 190 # 11' - 18' Aluminized 4" Aluminized 40-4 Alum N/A 2
HL2 40-75 N or LP 75 / 50 40'-11' 22'-8" 190 # 11' - 18' Aluminized 4" Aluminized 40-4 Alum N/A 2
HL2 40-100 N or LP 100 / 65 40'-11' 22'-8" 190 # 12' - 20' Aluminized 4" Aluminized 40-4 Alum N/A 4
HL2 40-125 N or LP 125 / 95 40'-11' 22'-8" 190 # 13' - 23' Aluminized 4" Aluminized 40-4 Alum N/A 4
HL2 40-150 N or LP 150 / 100 40'-11' 22'-8" 190 # 14' - 25' Titanium Coated 4" Aluminized 40-4 Titan N/A 4
HL2 40-175 N or LP 175 / 125 40'-11' 22'-8" 190 # 15' - 27' Titanium Coated 4" Aluminized 40-4 Titan N/A 4
HL2 50-125 N or LP 125 / 95 50'-7' *27'-4" 235 # 15' - 27' Aluminized 4" Aluminized 40-4 Alum 10-4 Alum 4
HL2 50-150 N or LP 150 / 100 50'-7' *27'-4" 235 # 15' - 27' Titanium Coated 4" Aluminized 40-4 Titan 10-4 Alum 4
HL2 50-175 N or LP 175 / 125 50'-7' *27'-4" 235 # 16' - 30' Titanium Coated 4" Aluminized 40-4 Titan 10-4 Alum 2
HL2 50-200 N or LP 200 / 145 50'-7' *27'-4" 235 # 17' - 35' Titanium Coated 4" Aluminized 40-4 Titan 10-4 Alum 2
HL2 60-150 N or LP 150 / 100 60'-3' 32'-4" 265 # 16' - 30' Titanium Coated 4" Aluminized 40-4 Titan 20-4 Alum 2
HL2 60-175 N or LP 175 / 125 60'-3' 32'-4" 265 # 16' - 30' Titanium Coated 4" Aluminized 40-4 Titan 20-4 Alum 2
HL2 60-200 N or LP 200 / 145 60'-3' 32'-4" 265 # 17' - 35' Titanium Coated 4" Aluminized 40-4 Titan 20-4 Alum 2
HL2 70-175 N or LP 175 / 125 69'-11" *37'-2" 300 # 19' - 42' Titanium Coated 4" Aluminized 40-4 Titan 30-4 Alum 2
HL2 70-200 N or LP 200 / 145 69'-11" *37'-2" 300 # 19' - 42' Titanium Coated 4" Aluminized 40-4 Titan 30-4 Alum 2

0 MOUNTING ANGLE
TOP
45 MOUNTING ANGLE
BELOW
FRONT BEHIND
TOP
BELOW
SIDE SIDE
0 W/1 SIDE SHIELD
TOP
0 W/2 SIDE SHIELDS
BELOW
SIDE SIDE
BELOW
TOP
FRONT BEHIND
HL2Series V.6/03- 4” Tube Heater Installation,Operation, Maintenance andParts Manual
HL2 Series
Failure to comply with the stated clearances
tocombustibles could result in personal injury,
death and/or property damage.
This heater should be installed so that the
minimum clearances to vehicles, as marked
on the heater, will be maintained. If vehicle
liftsare present, ensure that theseclearances
will be maintained from the highest raised
vehicle.
2
!WARNING!
!WARNING!
!WARNING!
!WARNING!
!WARNING!
This heater must be installed and serviced by
trained gas installation and service personnel
only. Read and understand these instructions
thoroughly before attempting to install, operate
or service this heater. Failure to comply could
result in personal injury, asphyxiation, death,
fire, and/or property damage. Retain these
instructions for future reference.
HL2 Series Mechanical Instructions
NOTFOR RESIDENTIAL USE!
Do not use in the home, sleeping quarters,
attachedgarages, etc.
In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to
maintain the required clearances from the
heater to the combustibles. Signs must either
be posted adjacent to the heater thermostats or
inthe absence of such thermostats, in a
conspicuouslocation.
This is not an explosion-proof heater. Where
there is the possibility of exposure to flammable
vapors, consult the local fire marshal, the fire
insurance carrier and other authorities for
approval of the proposed installation.
!WARNING!
FRONT BEHIND
0º 9 9 6 60
45º 39 8 10 60
W/1 side shield 0º 29 8 6 60
W/2 side shields 0º 9 9 6 60
20 ft from burner 0º 7 7 6 30
0º 14 14 6 66
45º 39 8 10 66
W/1 side shield 0º 29 8 6 66
W/2 side shields 0º 16 16 6 66
20 ft from burner 0º 7 7 6 30
0º 20 20 6 76
45º 58 8 10 76
W/1 side shield 0º 42 8 6 76
W/2 side shields 0º 20 20 6 76
20 ft from burner 0º 7 7 6 30
0º 24 24 6 81
45º 58 8 10 81
W/1 side shield 0º 42 8 6 81
W/2 side shields 0º 23 23 6 81
20 ft from burner 0º 11 11 6 44
0º 34 34 6 92
45º 63 8 10 92
W/1 side shield 0º 50 8 6 92
W/2 side shields 0º 30 30 6 92
20 ft from burner 0º 11 11 6 44
0º 41 41 6 94
45º 63 8 10 94
W/1 side shield 0º 54 8 6 94
W/2 side shields 0º 30 30 6 94
20 ft from burner 0º 11 11 6 44
CLEARANCES TO COMBUSTIBLES (IN.)
MODEL NO. SIDE TOP BELOW
MOUNTING
ANGLE
HL2 (40,50,60,70) - 175 [N,P]
HL2 (50,60,70) - 200 [N,P]
HL2 (20,30,40) - 65, 75 [N,P]
HL2 (20,30,40) - 100 [N,P]
HL2 (30,40,50) -125 [N,P]
HL2 (40,50,60) - 150 [N,P]

3
HL2SeriesV.6/03-4” TubeHeater Installation,Operation, MaintenanceandPartsManual
HL2 Series Mechanical Instructions
ProductSummary
HL2 Series heaters are available from 20 to 70 foot, 65,000 to 200,000 BTU’s, natural or LP gas. HL2
Seriesarepositive pressure, two-stageheatersthat feature aluminizedsteelfor it’s radiantpipes.
OperationalFeatures
HL2Seriesheatersrequirea 24 Volt, two-stage thermostatto operate. Each heater has a roundterminal
strip(oryellow cord)that acceptsthree1/4 in.insulatedspade terminalsforthe thermostatwiring. Do not
install 120V to this 24V connection.
Therearetwo versionsofthe HL2Series. Thestandard versioncomeswithout arelayboard (HLRB)and
the other issupplied with arelay board (HLRB) installed. AHL2 Series unit without arelayboard(HLRB)
suppliesit’sowncontrolvoltageandisidentifiedby thewhitebandlocatedaroundtheterminal plug. Ifunits
are common vented or if two or more models are to be controlled by a single thermostat, they must be
factoryassembled withrelayboards(HLRB)and installedusing anexternaltransformer(fieldsupplied) as
shown on page 6. AHL2 Series unit with a relay board (HLRB) installed is identified by the orange band
aroundthe terminalstrip.
Onstainlesssteelheaters,unitswitharelayboard(HLRB)willbelabeledaccordingly. Allmodelsassembled
withaHLRB referencethesuffix “D”onthe AGAratingplate.
SpecificMechanicalInstructions
Besure toindentifythetitaniumcoatedcombustionchamber(150-200MBTU/H)andplaceasthe firsttube
sectiondirectlyfollowingtheburner box. Theidentificationstickerfoundon theswaggedendofthe tubing
willidentifythetitaniumcoated combustiontube.
175,000and 200,000BTU/HModelsmustbe installedwith astainlesssteeltubeclamp atthe secondjoint
oftheexchangerbetweenthe firstandsecond radianttubes.
Notebaffle quantitiesforyour modeland placebafflesinthelast tubes(farthestfromtheburner) asshown
onpages13-14 ofthegeneral manual,andbelow (*).
Thissupplementis designedtoaddress thespecificsoftheHL2Series- seepage12 forproductfeatures.
(50-100 MBTU/H)
Aluminized
(50-125 MBTU/H)
Aluminized
Aluminized or Titanium
Aluminized or Titanium
Aluminized or Titanium
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
B
B
B
B
B
*
*
*
*
*
Aluminized or Titanium
B
Aluminized Aluminized Aluminized Aluminized Aluminized Aluminized
*
(50-125 MBTU/H) (150-175MBTU/H)
(50-125 MBTU/H) (150-200 MBTU/H)
(50-125 MBTU/H) (150-200 MBTU/H)
(50-125 MBTU/H) (150-200 MBTU/H)
Tube Installation Sequence
B = Burner Location * Baffle Location

4
HL2Series V.6/03- 4” Tube Heater Installation,Operation, Maintenance andParts Manual
HL2 Series
Electrical Requirements
♦120 Volt - 60 Hz GRD, 3-wire.
♦24Vthermostat connection.
♦Startingcurrent 4.8 amps
♦Runningcurrent 1.1amps
Gas Requirements
♦ Manifold Pressure
• Nat. 3.5’’ • LP. 10.0’’
♦ Minimum Inlet Pressure
• Nat. 5.0’’ • LP. 11.0’’
♦ Maximum Inlet
• Nat. 14.0’’ •LP. 14.0’’
Ventilation Requirements
♦Consultthe generalmanual forventing instructions.
♦For unvented operation, there must be a positive air
displacementofatleast4.0CFMper1000BTU/Hfornatural
gas or 4.5 CFM per 1000 BTU/H for LP gas. WVE-4
termination cap must also be used.
Theory of Operation
Standby:
TheMicro 60U24control continually checksfor internalfaults,
safety circuit integrity, and relay contact positioning.
Starting Circuit:
Upon a call for heat, the control will verify that the differential
safetypressure switch isin the properposition. The fan relay
energizes the fan, an operational static pressure is achieved
and the normally open differential pressure switch will close,
initiatingthe ignitionsequence. The glow-bar ispowered and
after 45 seconds the main gas valve opens. If flame is not
established the heater will attempt to re-ignite for a total of
three trials for ignition and then proceed to lockout.
First Stage Running Circuit:
Afterignition theflame-rod monitors the main burnerflame. If
flameis lost, the control actsto close thegas valve withinone
second and a new trial sequence, identical to the start up
sequence, is initiated. If proof is not established within 8.5
seconds,the unit willretry 2additional ignitionsequences and
then proceed to hard lock-out. The control can be reset by
interruptingthe power sourceor at thethermostat.
Second Stage Running Circuit:
Stagetwoonthegasvalve ispowereddirectlyfromthesecond
stage of the thermostat. In order for the second stage to flow
the higher output, the first stage has to be energized as well.
Thethermostatwilldeterminewhichstageisrequiredtomaintain
thedesired comfortlevel.
Shut Down:
When the thermostat is satisfied the fan will enter into a 2
minutepost-purge cycle.
Soft Lockout:
In the event of an external interruption (wind, gas, etc.) the
heater will go into a “soft-lockout” feature. In this mode the
heater will attempt a normal start-up after approximately 15
minutes. Intheevent ofcontinuedproblems,the heaterwillgo
into a hard lock-out mode.
Lockout Codes:
In event of a component failure, a red LED diagnostic light
locatedontheburnerboxendpanel will flashacodeidentifying
the fault. Lockout codes are summarized in the table below.
Somefault codes havea time delay before theLED will flash.
Refer to the FAULT CODE DELAY on the chart to see the
approximatetime delay.
Note: Hardlockout LED CODE will appearupon completion
ofthe soft lockoutsequence of operation.
LED CODE FAULT STATUS FAULT CODE DELAY
Initial flash on power up,
then steady off Normal operation Immediate
Steady on Module failure / Internal fault Immediate
1 flash Ignition failure 30-32 minutes
2 or 3 flashes APS - Note: fan / intake / exhaust 10-12 minutes
4 flashes Solenoid valve fault / Leaky valve /
Flame am
p
lifier fault Immediate
No flash on 117V start up Transformer fault Immediate

5
HL2Series V.6/03 -4” Tube HeaterInstallation,Operation, Maintenanceand PartsManual
Internal Wiring Diagrams
LLWT38
LIGHTS
MICRO 60U-24 BLOCK DIAGRAM
120VAC
L1
L2
T'STAT
TERMINAL
2-STAGE T'STAT
(FIELD SUPPLIED)
OFF
NO
GAS VALVE
INDICATOR
BLOWER
IGNITOR
FLAME
ROD
TRANSFORMER
PRESSURE SWITCH
STATUS
LIGHT
MICRO 60U-24
APS1 (NO)
IGNITION MODULE
MICRO 60U-24
(FIELD SUPPLIED)
L2
FLAME
ROD
IGNITOR
120V
24V
BLOWER
117L
HSI HSI
FAN
MICRO 60U-24
TH
24V
LLWT38
GND
MODULE
IGNITION
APS2
APS1 APS1
APS2
VALVE
GND
117N 117N
PRESSURE SWITCH
L1 120VAC
MICRO 60U-24 LADDER DIAGRAM
T'STAT
INDICATOR
LIGHTS
APS1
GAS VALVE
PROBE
GND
2-STAGE T'STAT
(FIELD SUPPLIED)
TERMINAL
(FIELD SUPPLIED)
TRANSFORMER
STATUS
LIGHT

Note: If optional Black power
cord is installed then L1 is
Brown or Black and L2 is Blue
or White.
Additional wire needed on thermostats that
require constant power.
T-stat
24v N Low High
1/4 spade terminals
required - field
supplied
Ground Screw
on Burner Box
HI
LO
24V 21
(Observe Polarity)
120 Volt Power
L1 L2
Note: If optional yellow control cord is installed then the
following wire colors apply:
24v - Green
Low - White
High - Black
PANEL GROUND
White label
HL2 HEATER
BURNER BOX
Note: If optional yellow control cord
is installed then the following wire
colors apply:
Neutral- Green
Low - White
High - Black
Note: If optional Black power
cord is installed then L1 is
Brown or Black and L2 is Blue
or White.
Additional wire needed on thermostats that
require constant power.
EXTERNAL TRANSFORMER
-FIELD SUPPLIED
T-stat
120 V
24V
LO
1
LO
N
HI
2
HI
(Observe Polarity)
L1 L2
PANEL GROUND
120 Volt Power
24v N Low High
1/4 spade terminals required
- field supplied
1
1
LO
N
N
2
2
HI
PANEL GROUND
PANEL GROUND
Orange
label
Orange
label
Orange
label
HL2 HEATER
BURNER BOX
HL2 HEATER
BURNER BOX
HL2 HEATER
BURNER BOX
6
HL2Series V.6/03 - 4”TubeHeater Installation,Operation,Maintenance and PartsManual
HL2 Series
Field Wiring Diagrams
Single heater, single thermostat, no relay board (white label).
Multiple heaters, single thermostat, with a relay board (HLRB - orange label).

LLWT39
LLWT39
MICRO 60U-24
WITH HLRB RELAY BOARD
L1 120VAC
MICRO 60U-24 LADDER DIAGRAM - WITH RELAY BOARD
HL RELAY BOARD
PRESSURE SWITCHES
INDICATOR
LIGHTS
GAS VALVE
2-STAGE T'STAT
(FIELD SUPPLIED)
120V
24V
120/24V
TRANSFORMER
(FIELD SUPPLIED)
MICRO 60U-24 BLOCK DIAGRAM - WITH RELAY BOARD
T'STAT
TERMINAL
(FIELD SUPPLIED)
LIGHTS
INDICATOR
TRANSFORMER
IGNITOR
FLAME
ROD
OFF
ON
GAS VALVE
APS1 (NO)
HL RELAY BOARD
2-STAGE T'STAT
(FIELD SUPPLIED)
L2
120/24V
TRANSFORMER
(FIELD SUPPLIED)
T'STAT
TERMINAL
BLOWER
PRESSURE SWITCHES
(FIELD SUPPLIED)
TRANSFORMER
TH
GND
GND
PROBE
IGNITOR FLAME
APS1
GND
24V
APS2
VALVE
117N
APS2
APS1
117N
HSI
MODULE
IGNITION
MICRO 60U-24
117L
FAN
HSI
BLOWER
ROD
24V
120V
L2
LIGHT
STATUS
L1
120VAC
MICRO 60U-24
IGNITION MODULE
STATUS
LIGHT
7
Alternative Wiring Diagrams
HL2Series V.6/03- 4”TubeHeater Installation,Operation, Maintenance andParts Manual

8
Is the power at the
heater 120V?
Is the power across the
left and center terminal
on the TP-213-24V plug
24V?
Is the power across the 24V wire on the circuit
board and ground on the
circuit board 24V?
Find the source of the
electrical problem between
panel & heater. YES
NO
Is the power across the TH
wire on the circuit board
and ground on the circuit
board 24V?
YES
Is the inlet or the outlet of the unit
obstructed? I.e. ice, birds nest, dirt, etc.
YES
Check for loose wiring or restrictions in
hose connections to the pressure switch.
Are they ok?
NO Repair wiring or hose
connections.
NO
YES
YES
NO
Is there 120V on the primary side of the external transformer?
NO
Find the source of the
electrical problem between
panel & external
transformer.
NO
Is there 120V on the
primary side of the
internal transformer?
NO
External transformer is
faulty and must be replaced. The internal
transformer is
faulty and must be
replaced.
YES
NO
The relay board is faulty
and must be replaced.
Does the fan
blower turn
on?
NO
Is the circuit
board sending
120V to the fan?
Does the
ignitor warm up
and glow red? Is the ignitor
physically damaged?
NO
Replace ignitor.
YES
NO
Check voltage at ignitor during the ignition sequence (usually 30-45 seconds after power to heater). Is it 120V?
NO
Is the resistance
through the ignitor
45-400 ohms?
YES
YES
YES
Is there 24V on the
secondary side of the
external transformer?
Is there 24V to the
thermostat?
YES
The circuit board is
faulty and must be
replaced.
NO
YES
NO
Find source of electrical
problem between the external
transformer and thermostat.
YES
The thermostat or wiring is
faulty and should be
replaced or repaired.
The circuit board is faulty and must be replaced.
YES
NO
*
Is the fan obstructed?
YES
NO
Circuit board is faulty and
must be replaced.
Is there 24V on secondary side of transformer?
YES
NO
Transformer is faulty and
must be replaced.
Is the power across the middle (low) terminal (on the TP- 213-24V plug) and ground (a screw on the burner box) 24V?
NO
Thermostat or wiring from thermostat to heater is faulty and must be replaced.
Is there 24V across the TH and ground terminals on the circuit board?
YES
NO
Correct wiring.
YES
Repair the wiring between the transformer and the TP-213-24V plug.
Turn up thermostat
NO
YES
Does the heater have a relay board? See page 6 of HL-2 insert for details on how to determine if heater has a relay board.
NO
Is the power across the
left terminal (on the TP-
213-24V plug) and ground
(a screw on the burner
box) 24V?
Is the circuit board sending 120V to the fan?
YES
Is the fan obstructed?
YES
NO
Is there 120V on the
primary side of the
transformer?
NO
Replace bad circuit board.
YES
Remove obstruction.
YES
NO
Shaded boxes indicate
troubleshooting for heaters with Relay Boards (HLRB) installed.
YES
HL2 V.6/03 Troubleshooting Flow Chart
The fan is faulty and
must be replaced.
Is the pressure switch stuck
in the closed position.
YES
NO Replace
Switch.
NO
The fan is faulty and
must be replaced.
Remove
obstruction.
Is the pressure switch stuck
in the closed position.
NO
YES
Replace.

Remove obstruction.
After 10-12 minutes of non-operation
has passed, is there a flash code for ASP-
1 failure (2 or 3 flashes)? Replace the pressure switch after verifying the
following: * Baffle(s) is in the tube(s) farthest from the burner. * Heater, fan blower, squirrel cage, intake and exhaust are clean and free from dirt and obstructions. * The 4” air intake pipe does not exceed 20 feet and/or 2 elbows. * There is not a negative pressure experienced at the area of air intake (i.e. attic space, high-winds, very tight building).
YES
WARNING:
Bypassing any
switch is for testing
purposes only. Do
not leave switch
bypassed during
normal operation
or heater’s built-in
safety mechanisms
will be
compromised.
Replace circuit board.
NO
9
After ignitor is
warmed up, does gas
valve open? NO
Test for 24V at valve during valve opening period (usually 30-45 seconds after power to the heater). Is there 24V to valve for 8 seconds?
NO Possibly, the circuit board
and/or wiring harness is faulty. These should be replaced.
Check to make sure gas pressure is
within minimum and maximum inputs,
as indicated on AGA burner rating
label. Is gas pressure OK?
YES
Correct
problem.
NO
Replace gas
valve.
YES
YES
Does the burner
light?
NO Is the gas cock in
the ON position? YES
Correct
problem.
NO
Make sure gas lines were
purged of air.
YES
YES
Does the burner
stay on? NO Does the burner stay on for
approx. 8 seconds and then
shut off?
YES Is the heater properly grounded?
Is the heater’s polarity correct? YES With microammeter, check DC
voltage at flame rod. Is it greater
than 0.7 microamps? YES
Check to make sure
flame sensor wire is
OK and then replace
circuit board.
NO
Sensing rod is faulty or flame is
weak. Check to make sure heater
is operating at proper gas
pressure as indicated on AGA
burner rating label and then
replace sensing rod if needed.
NO
Correct problem.
NO
Does the burner
come on and then
turn off immediately
(1 or 2 seconds).
YES
Check to make sure that the gas pressure is within minimum and maximum inputs as indicated on the AGA burner rating label. Is gas pressure OK?
Correct
problem.
NO
Pressure switch may
be faulty or there is
a restriction in the
exhaust.
YES
YES
NO
The following can cause the heater to shut down: * Improper grounding * High winds * Taking combustion air from the attic * Dirty environment * Baffle improperly positioned * Fluctuating gas pressure
Does heater stay on until
call for heat ends?
YES
Troubleshooting ends.
Check to make sure gas pressure is
within minimum and maximum inputs,
as indicated on AGA burner rating
label. Is gas pressure OK?
Ifheaterdoes not go intohigh-fire mode, checkthe following.
On the outside of the heater, check for
24V across COM and HIGH on the
TP-213-24V plug. Is there 24V?
NO
Repair or replace faulty wiring or thermostat.
The relay board
is faulty and
must be replaced.
Measure the voltage across the red wire on the relay board and GND on the circuit board. Is there 24V?
The valve is faulty
and must be replaced.
YES
NOTE: To confirm the heater is not in high-fire mode, check the manifold pressure. If 3.5” natural or 10” propane, the light is faulty and should be replaced. If the manifold pressure ranges from 2.3” to 2.8” Natural (model dependent) and 6.0” to 7.5” Propane (model dependent), the heater is in low-fire mode and the troubleshooting steps described here should be followed.
NO
YES
*
See page 4 for fault
flash code signals.
**

82
105
106
1
10
9
67 66 44
122
68A
31B
200
204
208
55A
5
97
54
50
217
83
31B
212
76
223
11
205
222
21B
201
33B
20C
19B
12
804
218
NOPS
202
222A
221
828
303A
840
841
825
70
827
832
852
802
851
826
65I
26A
EmitterTube(s)
CombustionChamber
26B
26A
214
26E
26D
220
21B
HL2Series V.6/03- 4” Tube HeaterInstallation, Operation,Maintenance and PartsManual
HL2 Series
10
Parts Breakdown

11
HL2Series V.6/03- 4” Tube Heater Installation,Operation, Maintenance andParts Manual
Basic Parts List
HL2 SERIES PARTS LISTING
** 6’ TOTAL NEEDED TO COVER OUTER EDGES OFABURNER BOX.
TP# ITEM TP# ITEM
TP-1 CONTROL BOX COVER TP-111 5' ALUM. TUBE, PAINTED W/1 CLAMP TP-5 FLANGE GASKET TP-112 5' REFLECTOR TP-9 CONDUIT COUPLING TP-122 GASKET FOR AIR ORIFICE & AIR COLLAR TP-10 CONDUIT 4" X 1/2" TP-200 BURNER (50 TO 100 MBTU/H) TP-11 GLO-BAR IGNITOR BOX TP-201 BURNER (125 MBTU/H TO 200 MBTU/H) TP-12 GLO-BAR IGNITOR BOX COVER TP-202 16" BURNER TUBE W/ FLANGE TP-14 SIGHT GLASS GASKET TP-204 GAS ORIFICE - CONSULT FACTORY TP-15 SIGHT GLASS TP-205 GLO-BAR HOLDER TP-16 SIGHT GLASS WASHER TP-208 "Z" MOUNTING BRACKET TP-19B WIRE HANGER TP-212 1/2" X 3" PIPE NIPPLE TP-20C 120" REFLECTOR TP-217 PRESSURE BARB FITTING TP-21B TUBE CLAMP TP-218 EXHAUST PRESSURE TUBE (VINYL) TP-26A 10 FT. ALUMINIZED RADIANT/COMBUSTION TUBE TP-220 STAIN. STL. TUBE CLAMP (175 & 200 MBTU/H) TP-26B 10 FT. TITANIUM COATED COMBUSTION TUBE TP-221 GLO-BAR HOLDER GASKET TP-26D 10 FT. 304 STAINLESS RADIANT TUBE TP-222 FLAME ROD TP-26E 10 FT. 409 STAINLESS COMBUSTION TUBE TP-223 GAS MANIFOLD TP-31B MOUNTING BRACKET TP-303A END PANEL - RIGHT TP-33B 1/2" GAS COCK TP-802 END PANEL - LEFT TP-44 AIR ORIFICE W/SCREEN (CONSULT FACTORY) TP-804 CONTROL BOX TP-50 GLO-BAR IGNITOR TP-825 OPTIONAL HLRB RELAY BOARD TP-54 BURNER BOX CENTER PANEL TP-826 40VA TRANSFORMER (OLD TP219) TP-55A FAN BLOWER TP-827 RED LED DISPLAY DIAGNOSTIC LIGHT TP-65I 33" INTERLOCKING HEAT DIFFUSER (BAFFLE) TP-828 YELLOW OPERATIONAL IND. LIGHT (OLD TP216) TP-66 2" X 4" OUTLET BOX TP-832 THERMOSTAT TERMINAL STRIP (OLD TP213) TP-67 2" X 4" OUTLET BOX COVER TP-840 36E96-224 TWO STAGE GAS VALVE-NAT (OLD TP210) TP-68A STRAIN RELIEF BUSHING TP-841 36E96-226 TWO STAGE GAS VALVE-LP (OLD TP210P) TP-70 CONTROL BOX COVER GASKET (PER FOOT**) TP-851 MICRO-60-24 DIAGNOSTIC CIRCUIT BOARD TP-76 RUBBER GROMMET TP-852 WIRE HARNESS SET (3 PCS.) FOR MICRO 60 BOARD TP-82 REFLECTOR CENTER SUPPORT TP-NOPS N. O. Pressure Switch (Select Switch Below, BTU Dependent)
TP-83 STAINLESS STEEL FLEX CONNECTOR (TP-264B) DIFFERENRIAL PRESSURE SWITCH - 50 TO 100 MBTU/H TP-97 1/4" x 1/4" BRASS INT./EXT. ATMOS. BARB FITTING (TP-264E) DIFFERENTIAL PRESSURE SWITCH - 125 & 150 MBTU/H TP-105 REFLECTOR END CAP (TP-264D) DIFFERENTIAL PRESSURE SWITCH - 175 MBTU/H TP-106 REFLECTOR CLIP (TP-264F) DIFFERENTIAL PRESSURE SWITCH - 200 MBTU/H TP-108 5' AL-TI TUBE, PAINTED W. ONE CLAMP

HL2 SERIES KIT CONTENTS
TP# DESCRIPTION 20 FOOT 30 FOOT 40 FOOT 50 FOOT 60 FOOT 70 FOOT
TP-19B4"Hangers 345678
TP-21B 4" Tube Clamps 2 3 4 5* 6* 7*
TP-33B 1/2" Gas Cock 1 1 1 1 1 1
TP-824"Refl.Cntr.Sprt.234567
TP-83 24" SS Flex Line 1 1 1 1 1 1
TP-105Refl.Endcaps 222222
TP-106Refl.EndcapClips888888
IOMInstall/OpManual111111
FILLED BY:
HL2Series V.6/03- 4” Tube Heater Installation,Operation, Maintenance andParts Manual
Kit Contents & Product Features
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Product Features
Kit contentsforthe HL2Seriesare shownbelow. Reference thepropercolumn foryourparticular models length.
APPROVALS
•IAS,CSA,CGA,CE.
•Indoor approval.
•Outdoor approval with OD-Kit.
•Commercialapproval.
BURNERSIGHTGLASS
•For burner inspection.
COMBUSTIONAIRINLET&VENT
•4” Male duct.
ENAMELEDCONTROLBOX
•Outside air collar (4”) attached.
•Totally enclosed components.
CONTROLS
•100% safety shut off.
•Differential pressure switch.
•Silicon carbide hot surface igniter.
•Flame rod sensing.
•Pre and post purge controls.
•Microprocessor circuit board provides
soft lockout and self-diagnostic features.
EMITTER&COMBUSTIONTUBES
•16ga.4” O.D.aluminized steel.
•All tubes coated with high temperature,
corrosion resistant black coating .95
emissivity. Slip fit connection.
•Titanium treated combustion chamber
(150-200MBTU/Hmodels).
GASCONNECTION
•1/2” gas cock included.
•7/8”flare-2’S.S. flexincluded.
RADIANTSURFACEAREA(SQ.FT.)
••
••
•20’ Models – 20.2 • 50’ Models – 50.6
•30’ Models – 30.4 • 60’ Models – 60.7
•40’ Models – 40.5 • 70’ Models – 70.9
WARRANTY
1 year - Burner box components.
5 years - Combustion and radiant tubes.
10 years - Stainless steel burner.
4"Hanger
TP-19B
Gas Cock
1/2" TP-33B
General IOM
(LIOGT)
AND
HL2 Series Insert
(LIOHL2)
Reflector End
Caps TP-105
Notes
*One 4” stainless steel butt clamp is provided for each 175,000-
200,000 BTU model. Place as shown in IOM.
Bag of Reflector
End Cap Clips.
TP-106
24"SSFlex
Connect TP-83
4” Reflector Center
Support - TP-82
OTHER
••
••
• One reflector center support per reflector.
••
••
• Turbulator baffle included.
••
••
• Stainless steel upgrades available.
••
••
• Made in U.S.A.
4” Butt Clamp
TP-21B