Detroit Radiant Products HLV Series User manual

Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, injury, or death. Read the installation, operation, and
maintenance instructions thoroughly before installing or servicing this equipment.
This heater must be installed and serviced by trained gas installation and service
personnel only. Failure to comply could result in personal injury, asphyxiation,
death, re, or property damage.
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, in the absence of such thermostats, in a
conspicuous location.
Not for residential use! Do not use this heater in the home, sleeping quarters,
attached garages, etc. Installation of a commercial tube heater system in
residential indoor spaces may result in property damage, serious injury,
asphyxiation, or death.
WARNING
!
HLV Series Tube Heater
Vacuum System
For Your Safety
If you smell gas:
• Do not try to light any appliance. • Immediately call your gas supplier from a neighbor’s phone.
• Do not touch any electrical switch. • Follow the gas supplier’s instructions.
• Do not use any phone in your building. • If you cannot reach your gas supplier, call the re department.
The HLV Series Infrared Tube Heater is a negative pressure, two stage radiant heater vacuum system
designed to provide comfort heat. Consisting of four main components (a burner control box, radiant
tubes, reector assembly, and vacuum exhauster), this system generates infrared energy to heat the
objects in the space. These objects then reradiate this heat, creating a comfort zone at the oor level.
This allows large spaces to be heated eciently without having to provide primary infrared for every
square foot of space.
Design, Installation, Operation, and Maintenance Manual
LIOHLV-Rev. 21711
Print: 2M-02/17_r5-03/21 (CDS)
Replaces: LIOHLV-2M-3/15(CDS)
INSTALLER: Present this manual to the end user.
Keep these instructions in a clean and dry place for future reference.
Model#:______________________ Serial #: _____________________________
(located on rating label)

2
HLV Series
Contents
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standards, Certications, and Government Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Labels and Their Locations........................................................6
Clearances to Combustibles..............................................................8
2.0 Design ..........................................................................................10
Pre-Design...............................................................................10
Design for Non-Condensing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Design for Condensing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
System Design Denitions...............................................................14
Typical System Layouts..................................................................15
Vacuum Pump Application...............................................................18
Damper Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Pre-Installation ..........................................................................20
Vacuum Pump Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Tube Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Elbows and Intersections ................................................................25
Turnbuckle Suspension..................................................................26
Bae Assembly and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Reector Assembly ......................................................................28
Burner Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Venting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Combustion Air Requirements...........................................................33
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Wiring....................................................................................35
Gas Supply...............................................................................39
4.0 Operation.......................................................................................42
Lighting and Shutdown ..................................................................42
Sequence of Operation ..................................................................42
Thermostat ..............................................................................43
Diagnostics ..............................................................................43
System Start-Up Prechecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Damper Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
5.0 Maintenance....................................................................................45
Routine Inspection.......................................................................45
Troubleshooting Guide ..................................................................46
Replacement Parts ......................................................................50
6.0 Limited Warranty ...............................................................................52
Table of Contents

Overview
The intent of this manual is to provide information regarding general safety, installation, operation, and
maintenance of the tube heater vacuum system. You must read and understand the instructions and
safety warnings in this manual before installing the heating system.
System Components*
Prior to installation, verify that the heater’s gas type and voltage (as listed on the rating plate) match that
of your application. Also verify that you have received all heater contents included with your system by
checking them against the packing list. Materials not included in the heater kit contents (i.e. screws,
vent material, terminals, etc.) are the responsibility of the installer. Notify your product representative or
Detroit Radiant Products of any discrepancy or missing kit contents prior to installing unit.
1.0 Introduction
Figure 1.1 •Typical System Components*
* Each HLV Series vacuum system
is engineered specic to each
application’s design parameters.
Some items illustrated may not
be required with all system
designs.
Tube Hanger
(TRP)
Standard
Reector
(TRP)
Reector Center
Support
(TRP)
Primary/Secondary
Combustion Chamber(s)
(TRP)
Baes
(VPK)
Reector End
Cap w/Clips
(BRN)
Tube Clamp
(BRN & TRP)
Burner Control Box
SS Flex Connector
(BRN)
Shut-o Valve
(BRN)
KEY:
BRN - Comes with burner box
TRP - Comes with tube and reector packages
VPK - Comes with vacuum pump kit
ACY - Sold as an optional accessory
Radiant
Tube(s)
(TRP)
Ignitor/
Sensor Box
(BRN)
Chain Set
(ACY)
16” Burner Tube
(BRN)
Reector
Tension
Spring
Isolation Boot
(VPK)
Turnbuckle
(ACY).
Vacuum Pump
Primary
Damper
(VPK)
3
HLV Series 1.0 Introduction •Overview •System Components
Refer to pages 50-51 for a complete parts breakdown.

4
HLV Series
1.0 Introduction • Specications
Burner
Model
Gas
Type
BTU/h
(High Fire)
BTU/h
(Low Fire)
Approximate Component
Hanging Weights
Typical
Mounting
Height^
Combustion
Chamber
(Black Coated)
Radiant
Emitter
Tube(s)**
Condensing
Pipe
Per
Burner
Head
Per 10 Ft.
Radiant Pipe
& Reector
Section
Per 10 Ft.
Tailpipe &
Reector
Section
HLV-40* N or P 40,000 40,000 35 lbs. 35 lbs. 45 lbs. 9’ to 14’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-50* N or P
50,000 50,000 35 lbs. 35 lbs. 45 lbs. 9’ to 14’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV- 60 N or P
60,000 50,000 35 lbs. 35 lbs. 45 lbs. 10’ to 15’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-75 N or P
75,000 60,000 35 lbs. 35 lbs. 45 lbs. 11’ to 18’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-80 N or P
80,000 64,000 35 lbs. 35 lbs. 45 lbs. 11’ to 18’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-90 N or P
90,000 72,000 35 lbs. 35 lbs. 45 lbs. 12’ to 20’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-100 N or P
100,000 80,000 35 lbs. 35 lbs. 45 lbs. 12’ to 20’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-110 N or P
110,000 88,000 35 lbs. 35 lbs. 45 lbs. 13’ to 23’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-120 N or P
120,000 96,000 35 lbs. 35 lbs. 45 lbs. 13’ to 25’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-125 N or P
125,000 100,000 35 lbs. 35 lbs. 45 lbs. 14’ to 27’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-140 N or P
140,000 112,000 35 lbs. 35 lbs. 45 lbs. 15’ to 30’ Al-Ti Coated Alum or
Uncoated HRT
304 Stainless
Steel
HLV-150 N or P
150,000 120,000 35 lbs. 35 lbs. 45 lbs. 15’ to 30’ Al-Ti Coated Alum or
Uncoated HRT**
304 Stainless
Steel
HLV-170 N or P
170,000 136,000 35 lbs. 35 lbs. 45 lbs. 16’ to 40’ Al-Ti Coated Alum or
Uncoated HRT**
304 Stainless
Steel
HLV-175 N or P
175,000 140,000 35 lbs. 35 lbs. 45 lbs. 17’ to 42’ Al-Ti Coated Alum or
Uncoated HRT**
304 Stainless
Steel
HLV-180 N or P
180,000 144,000 35 lbs. 35 lbs. 45 lbs. 18’ to 47’ Al-Ti Coated Alum or
Uncoated HRT**
304 Stainless
Steel
HLV-200 N or P
200,000 160,000 35 lbs. 35 lbs. 45 lbs. 19’ to 50’ Al-Ti Coated Alum or
Uncoated HRT**
304 Stainless
Steel
Chart 1.1 • HLV Series Specications
* The HLV-40 and HLV-50 do not have a reduction for low re.
** All systems are designed to utilize either black coated aluminized steel (Alum) or uncoated hot-rolled steel (HRT)
radiant emitter tubes. On systems designed with the hot-rolled steel option, a coated aluminized steel radiant
tube (TP-26A) must be installed immediately downstream of the titanium stabilized aluminized steel (Al-Ti)
combustion chamber (TP-26B) on burner models HLV-150, 170, 175, 180, and 200 only.
^ Recommended mounting heights are provided as a guideline. Actual conditions may dictate variations from this
data.
NOTE: Burner models HLV-150, 170, 175, 180 and 200 receive TP-220 stainless steel tube clamp.
Specications

5
HLV Series 1.0 Introduction • Standards, Certications, and Government Regulations •Applications
This is not an explosion proof heater. No tube heater may be used in a Class 1 or Class 2 Explosive
Environment. Consult your local re marshal, insurance carrier, and other authorities for approval if the
proposed installation is in question.
Commercial/Industrial: Unless otherwise indicated, tube heaters are designed and certied for use
in commercial and industrial buildings such as warehouses, manufacturing plants, aircraft hangars,
and vehicle maintenance shops. For maximum safety the building must be evaluated for potential
problems before installing the heating system. A critical safety factor to consider before installation is
the clearances to combustibles (see pages 8-9).
Public Garages: Installation of this tube heater in public garages must conform with the Standard for
Parking Structures NFPA 88A (latest edition) or the Code for Motor Fuel Dispensing Facilities and Repair
Garages NFPA 30A (latest edition).
• Heaters must not be installed less than 8 ft. (2.4 m) above the oor. Minimum clearances to
combustibles must be maintained from vehicles parked below the heater.
• When installed over hoists, minimum clearances to combustibles must be maintained from the
upper most point of objects on the hoist.
Aircraft Hangars: Installation of this tube heater in aircraft hangars must conform with the Standard
for Aircraft Hangars, ANSI/NFPA 409 (latest edition).
• In areas adjoining the aircraft storage area (e.g., shops, oces) the bottom of heaters shall be
installed no less than 8 ft. (2.4 m) above the oor.
• Suspended or elevated heaters shall be located in spaces where they shall not be subject to
damage by aircraft, cranes, movable scaolding, or other objects.
High Altitude: Installation of this tube heater is approved, without modications, for elevations up to
6,000 feet (1,829 m) MSL (sea level) in the United States. Contact the factory for installations above
these elevations.
Installation of this tube heater must comply with all applicable local, state, and national specications,
regulations, and building codes. Contact the local building inspector and/or re marshal for guidance.
In the absence of local codes, the installation must conform to the latest edition of:
United States: National Fuel Gas Code, ANSI Z223.1 (NFPA 54)
Canada: CAN/CGA B149.1 and .2, Canadian Electrical Code C22.1
• ANSI - American National Standards Institute
• OSHA - Occupational Safety & Health Administration
• CSA - Canadian Standards Association
• Indoor approval
WARNING
!
!
Not For Indoor Residential Use. Installation of an infrared heater
system in residential indoor spaces may result in property damage,
serious injury, or death. In residential applications this heater may only
be used outdoors.
Standards, Certications, and Government Regulations
Applications

Top Panel
Bottom Panel
F/N: LLTCL012
Clearances to Combustibles Label
F/N: LLLOGO32
Logo Label
Burner Control Box
Component Label
(Located under the top panel)
Safety warning labels must be maintained on the heating system. Safety labels and their locations are
illustrated below and on page 7. Product safety signs or labels should be replaced by the product user
when they no longer are legible.
It is important to provide warnings to alert individuals to potential hazards and safety actions. ANSI
Z83.20 and CSA 2.34 require you to post a sign near the heater’s thermostat, or the in absence of
such thermostat, in a conspicuous location “specifying the maximum permissible stacking height to
maintain the required clearances from the heater to combustibles.” A Clearance Safety Tag (F/N:
LL001) is provided with each burner control box (see page 7). Contact Detroit Radiant Products
Company or an authorized distributor for obtaining safety signs or replacement labels and tags.
HLV-40-125N
Data on this label is for the model shown on this label. If your heater has been converted, this
information is not accurate. Please contact the factory for assistance.
BURNER COMPONENTS:
For parts replacement information, contact factory at 586-756-0950 or visit www.drp-co.com/parts.
Serial No.: 0807XXXXXXXXXX 0001
Gas Valve:
Circuit Board:
Wire Harness:
N.O. Switch:
N.O. VL Orifice:
N.C. Switch:
N.C. VL Orifice:
Diff Switch:
Diff VL Orifice:
Igniter:
Burner:
16” Tube:
Ind. Lights:
Diag. Light:
Term. Block:
Transformer:
Fan:
Alt. Fan:
Alt. Fan Usage:
Relay:
Filter:
24 Volt In:
120 Volt In:
Gas In:
Extra VL Orifice:
Production Code:
Version:
Stock:
Add-On:
Internal Use Only:
HEATER
TYPE: Electric:
Tag:
Special 1:
Special 2:
Gas:
Air:
C1
C1 C2 C3
None
N/A
HLV-125
5.05
36G54-224-N
6465H
3 PCS Harness
None
None
None
None
IS22016051F5169
Grey (+ / -)
Norton
High
4” Stnd.
Yellow - 24V
(Specify TP-#’s)
1540A
1251
3-PCS Harness
N/A
N/A
264E
50
201B
380
828
Red LED
None
40 VA
Fasco Lg.
50Hz - 120V
When Specified
Picker x2
None
3 T-plug
2x4 Box
7/8” FC
None
827
N/A
826
55A
55B
1527
N/A
832
66
83
3
1 1/2”
TP-204#
TP-44#
3
1 5/8”
LLWT038
None
1
1 5/8”
17
1 7/16”
Orifice Type:
SAMPLE
Safety Labels and Their Locations
6
HLV Series
1.0 Introduction •Safety Labels and Their Locations
WARNING
!
Read and understand the installation, operating, and maintenance instructions
thoroughly before installing or servicing this equipment.
Only trained, qualied gas installation and service personnel may install or service
this equipment.

F/N: LLV3EP2
24 V Input
Orange Crescent
®
DETROIT RADIANT PRODUCTS COMPANY
21400 HOOVER ROAD - WARREN, MI
RE-VERBER-RAY INFRA-RED RADIANT TUBE HEATER
FOR OUTDOOR USE AND INDOOR (Non-Residential) INSTALLATION ONLY.
Class IIIA Permanent Label
[phone] - www.drp-co.com
Volts AC:
AMPS - Starting:
AMPS - Running:
Combustion Chamber:
120V - 60Hz
4.8
1.1
4” Black Coated Aluminized For stainless steel upgrades: The combustion tube is 409 Series stainless steel.
DESIGN COMPLIES WITH:
ANSI Z83.20b-2004-GAS FIRED LOW INTENSITY INFRA-RED HTR.
Manifold Pressure:
Maximum Inlet Pressure:
Minimum Inlet Pressure:
3.5 in.
14 in.
5.0 in.
W.C.P.
W.C.P.
W.C.P.
Serial No.: 0807XXXXXXXXXX 0001
MODEL NO.
HLV-40-125N
Heater Type
Minimum Mounting Angle:
Maximum Mounting Angle:
C1
0
45
DEGREES
DEGREES
INPUT BTU/H
125,000 / 95,000
FOR USE WITH
Natural Gas
SAMPLE
7
HLV Series
SERVICE ACCESS PA NEL
IGNITER & FLAME SENSE COMPARTMENT
1. Turn off gas & electricity.
2. Remove cover by lifting top
cover upward and outward.
CAUTION: HOT SURFACE.
KEEP COVER IN PLACE. REMOVE FOR SERVICE ONLY.
SERVICE ACCESS PANEL
IGNITER & FLAME SENSE COMPARTMENT
1. Turn off gas & electricity.
2. Remove cover by lifting top
cover upward and outward.
CAUTION: HOT SURFACE.
KEEP COVER IN PLACE. REMOVE FOR SERVICE ONLY.
F/N: LLTB026
Right Panel
(Valve Compartment)
Radiant
Tube(s)
Combustion
Chamber
16” Burner Tube
Left Panel
(Controls Compartment)
AVOID EQUIPMENT FAILURE
THIS 10 FT. TUBE IS THE
COMBUSTION CHAMBER.
THIS TUBE MUST BE THE FIRST TUBE
FOLLOWING THE BURNER CONTROL BOX.
!
INSTALLER
The combustion chamber utilizes either 409
stainless, titanium alloy or aluminized steel -
depending on the model number of your heater.
Rotate the tube’s welded seam to bottom.
Consult the manual(s) for further details.
F/N: LLTB004 (orange)
F/N: LL001 - Clearance Safety Tag
(Ax adjacent to heater’s thermostat)
Clearances to combustibles must be maintained at
all times in order to prevent the ignition of
combustible materials. 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’s thermostats or, in the absence of such thermostats, in a
conspicuous location. Clearances are provided on the heater’s
safety label and in the heater’s Installation, Operation, and
Maintenance manual. Product installation and operation must
comply with applicable standards, codes, and regulations. Post
this tag adjacent to the heater’s thermostat or controls before
operating the heater.
- INSTALLER: READ AND POST THIS NOTICE -
LL001-XM-07/18 (CDS)
This product can
expose you to
chemicals including
lead and carbon
monoxide, which are known to the
State of California to cause birth
defects or other reproductive harm.
For more information go to
www.P65Warnings.ca.gov.
WARNING
!
Avoid Serious Injury, Death, or Property Damage.
Maintain Clearances to Combustible to Prevent the Risk of Fire.
California Proposition 65
F/N: LLV2EP9
Operational Indicator Lights
1.0 Introduction •Safety Labels and Their Locations
NEUTRAL
EARTH
HOT
-120V HEAT ER INPUT -
120V
Back Panel
Rating Plate
F/N: LLTB018 (Natural Gas)
F/N: LLTB019 (Propane Gas)
NEUTRAL
EARTH
HOT
- 120V HEATER INPUT -
120V
F/N: LLV3EP1
120 V Input
Air Metering Orifice
DO NOT REMOVE
TP-114
TP-3014 3”
F/N: LLAC
Air Metering Orice
SAMPLE
F/N: LLV2EP15

WARNING
!
Placement of explosive objects, ammable objects, liquids, and vapors
close to the heater may result in explosion, re, property damage, serious
injury, or death. Do not store or use explosive objects, liquids, or vapor in
the vicinity of the heater.
Clearances to combustibles is dened as the minimum distance that must exist between the tube
surface, or reector, and any combustible items (see Figure 1.2). It also pertains to the distance that
must be maintained from moving objects around the tube heater. Moving items include, but are not
limited to, vehicle lifts, overhead doors, cranes, and hoists. For instance, if vehicle lifts are present,
ensure that clearances will be maintained from the highest raised vehicle.
If you are unsure of the potential hazards in the application, consult your local re marshal, insurance
carrier, or other qualied authorities on the installation and approval of the proposed installation.
Clearances listed in Chart 1.2 on page 9 apply to each individual burner in the HLV system. When
installing the tube heater vacuum system, clearances to combustibles for each burner model and its
applicable tube run must be maintained. Inspect each burner rating label to ensure that clearances
are maintained.
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
combustibles. Signs must be posted adjacent to the heater’s thermostat or, in the absence of such
thermostat, in a conspicuous location.
The stated clearances to combustibles represents a surface temperature of 90°F (50°C) above room
temperature. Building materials with a low heat tolerance (i.e. plastics, vinyl siding, canvas, tri-ply, etc.)
may be subject to degradation at lower temperatures. It is the installer’s responsibility to ensure that
adjacent materials are protected from degradation.
Clearances to Combustibles
8
HLV Series
Failure to maintain minimum clearances to combustibles may result in re and/or
explosion, property damage, serious injury, or death. Always maintain minimum
clearances and post clearance safety limit signs or the clearance safety tag where
needed.
WARNING
!
1.0 Introduction •Clearances to Combustibles
Figure 1.2 •Mounting Angles
0° Mounting Angle 45° Mounting Angle
0° Mounting Angle
with 1 Side Shield
(P/N: SSE)
0° Mounting Angle
with 2 Side Shields
(P/N: SSE)
Side Side
Below
Top
Front Behind
Below
Top
Front Behind
Below
Top
Side Side
Below
Top

9
HLV Series
Model Number
Mounting
Angle*
Sides
Front Behind Top* * Below
HLV-40, HLV-50 [N, P] 0° 99447
45° 39 810 47
with 1 side shield 0° 29 8 4 47
with 2 side shields 0° 99447
20 ft. from burner 0° 77430
HLV-60, HLV-75 [N, P] 0° 99448
45° 39 810 48
with 1 side shield 0° 29 8 4 48
with 2 side shields 0° 99448
20 ft. from burner 0° 77430
HLV-80 [N, P] 0° 11 11 448
45° 39 810 48
with 1 side shield 0° 29 8 4 48
with 2 side shields 0° 16 16 448
20 ft. from burner 0° 77430
HLV-90 [N, P] 0° 12 12 454
45° 39 810 54
with 1 side shield 0° 29 8 4 54
with 2 side shields 0° 16 16 454
20 ft. from burner 0° 77430
HLV-100 [N, P] 0° 14 14 466
45° 39 810 66
with 1 side shield 0° 29 8 4 66
with 2 side shields 0° 16 16 466
20 ft. from burner 0° 77430
HLV-110, HLV-120, HLV-125 [N, P] 0° 18 18 472
45° 58 8 10 72
with 1 side shield 0° 42 8 4 72
with 2 side shields 0° 20 20 472
20 ft. from burner 0° 77430
HLV-140, HLV-150 [N, P] 0° 24 24 681
45° 58 8 10 81
with 1 side shield 0° 42 8 6 81
with 2 side shields 0° 30 30 681
20 ft. from burner 0° 11 11 644
HLV-170, HLV-175 [N, P] 0° 34 34 692
45° 63 810 92
with 1 side shield 0° 50 8 6 92
with 2 side shields 0° 30 30 692
20 ft. from burner 0° 11 11 644
HLV-180, HLV-200 [N, P] 0° 41 41 694
45° 63 810 94
with 1 side shield 0° 54 8 6 94
with 2 side shields 0° 30 30 694
20 ft. from burner 0° 11 11 644
1.0 Introduction •Clearances to Combustibles
Chart 1.2 • Clearances to Combustibles in Inches (see Figure 1.2 for Mounting Angles)
*
Heaters mounted on an angle between 0° and 45° must maintain clearances posted for 0° or 45°, whichever is
greater.
**
Where there is an uncovered (no reector) tube, the top clearance to combustibles is 18 inches.

10
HLV Series
2.0 Design •Pre-Design
The HLV Series vacuum system can be designed as a non-condensing or a condensing system.
After reviewing the following pre-design guidelines, proceed to the appropriate section for the
desired system. If uncertain as to what type of system should be used, begin by designing for a
condensing system (see page 12). If the completed design does not require condensing pipe then,
by default, the system will become a non-condensing system. Refer to page 11.
1Most non-condensing systems should be controlled via a single temperature zone. If two zones
are required, it will be necessary in most cases to design the system as a condensing system
(see page 12). Contact the factory for additional guidelines.
2Determine the heat load requirement of the building.
3 Available mounting heights and coverage are the two most critical variables in input (BTU/h)
selection and quantity.
• The mounting height of the system determines the largest burner model that can be used.
• When the design is calculated, if it is discovered that the quantity of burners in the system will
not provide sucient coverage, it may be necessary to use a larger quantity of lower input
burners, sometimes resulting in the need for additional vacuum pumps.
4When determining system location, clearances to combustibles must be maintained. Items such
as lights, sprinkler heads, overhead doors, storage areas containing stacked materials, gas and
electrical lines, parked vehicles, cranes, and any other possible hazards must be taken into
account. Refer to Chart 1.2 on page 9 for Clearances to Combustibles distances.
IMPORTANT: Fire sprinkler heads must be located at an appropriate distance from the heater.
This distance may exceed the published clearances to combustibles as posted on the heater.
Certain applications may require the use of high temperature sprinkler heads or relocation of the
heaters.
Sprinkler systems containing propylene glycol or other potentially ammable substances are not
to be used in conjunction with this heater without careful consideration for, and avoidance of,
potential re or explosion hazards. For further information consult NFPA 13.
5 Reference page 14 for System Design Denitions.
2.0 Design
Pre-Design for Non-Condensing and Condensing Systems

Burner Model
Minimum Distance from
Burner to First Elbow or
Intersection
Calculated
Minimum Run*
Calculated
Maximum Run*
HLV-40, HLV-50, HLV-60 10 ft. 30 ft. 60 ft.
HLV-75, HLV-80 10 ft. 35 ft. 65 ft.
HLV-90, HLV-100 10 ft. 40 ft. 70 ft.
HLV-110, HLV-120, HLV-125 10 ft. 45 ft. 75 ft.
HLV-140, HLV-150 15 ft. 50 ft. 80 ft.
HLV-170, HLV-175, HLV-180 15 ft. 55 ft. 85 ft.
HLV-20 0 20 ft. 60 ft. 90 ft.
11
HLV Series 2.0 Design •Design for Non-Condensing Systems
Chart 2.1 • Design Parameters for Non-Condensing Systems (refer to page 14 for denitions).
System tube lengths are determined by the gas input (BTU/h) of each burner. Chart 2.1 below
indicates system design parameters for each burner model used in each system. When calculating
tube lengths, do not add in elbow and tee ttings as they have been accounted for.
Designing a non-condensing system can be fairly straightforward given the below steps are
followed carefully. In addition to these steps, an understanding of design denitions is critical.
Refer to page 14 for these terms and illustrations.
1Begin by designing a tentative layout without regard to design parameters. Use this approach to
place each burner and the vacuum pump where most desired (refer to Figures 2.4 - 2.10 for
typical layouts).
2 Once a tentative layout has been established, conrm that each run in the system meets the
criteria for ‘Calculated Minimum Run.’ ‘Calculated Minimum Run’ is determined by adding the
total ‘Single Flow’ plus one-half of the ‘Common Flow.’
• If the system does not meet the ‘Calculated Minimum Run’, length must be added to the run until
all burners meet the design parameters.
• If the run exceeds the ‘Calculated Maximum Run,’ it will be necessary to either make the system
a condensing system or shorten the runs which exceed this criteria.
3 Conrm the following applies (non-condensing systems only):
a) A maximum of two elbows per run is allowed per system.
b) A maximum of three intersections (tees or crosses) are allowed per system.
c) All elbows and intersections less than 20 feet from a burner require a reector.
* Be sure to account for runs where Tandem Tee Set (P/N: V-TTS) are used in the system.
NOTE: Contact the factory for approval when system design exceeds the guidelines set forth in the
table above.
Design for Non-Condensing Systems

12
HLV Series
2.0 Design •Design for Condensing Systems
Simulated In-Line Systems**
HLV Burner
Model
Minimum
Distance from
Burner to First
Elbow or
Intersection (Ft.)
Calculated
Minimum
Run (Ft.)*
Calculated
Starting Point
of Condensing
Run (Ft.)
Calculated
Maximum Run
(Including
Condensing
Pipe) (Ft.)
Maximum Actual
Distance Between
Tie-Ins for Simulated
In-Line Systems (Ft.)
Starting Point
(after last tie-in)
for Condensing for
Simulated In-Line
Systems (Ft.).
40, 50, 60 10 30 60 175 50 40
75, 80 10 35 65 200 55 50
90, 100 10 40 70 200 60 50
110, 120, 125 10 45 75 225 65 60
140, 150 15 50 80 225 70 60
170, 175, 180 15 55 85 250 75 70
200 20 60 90 250 80 70
Chart 2.2 • Design Parameters for Condensing Systems (refer to page 14 for denitions).
System tube lengths are determined by the gas input (BTU/h) of each burner. Chart 2.2 below
indicates system design parameters for each burner model used in each system. When calculating
tube lengths, do not add in elbow and tee ttings as they have been accounted for.
Designing a condensing system can be fairly straightforward given the below steps are followed
carefully. In addition to these steps, an understanding of design denitions is critical. Refer to page 14
for these terms and illustrations.
1Begin by designing a tentative layout without regard to design parameters. Use this approach to
place each burner and the vacuum pump where most desired (refer to Figures 2.4 - 2.10 for
typical system layouts).
2 Once a tentative layout has been established, conrm that each run in the system meets the
criteria for ‘Calculated Minimum Run.’ ‘Calculated Minimum Run’ is determined by adding the
total ‘Single Flow’ plus one-half of the ‘Common Flow.’
• If the system does not meet the ‘Calculated Minimum Run,’ length must be added to the run
until all burners meet the design parameters.
3Refer to Chart 2.2 to determine the ‘Calculated Starting Point of Condensing Run’ for each
individual burner run. All elbows and intersections that fall within the condensing section of run
must also utilize condensing pipe. If there are no runs long enough to utilize condensing pipe,
then the system is considered a non-condensing system.
IN-LINE SYSTEMS: If the system requires the simulation of in-line burners, all tie-in burners
(Figure 2.1) must be located no less than the ‘Minimum Distance from Burner to First Elbow or
Intersection’; also reference ‘Maximum Actual Distance Between Tie-Ins for Simulated In-Line
Systems’ to ensure the tie-in distance is not exceeded. Reference Chart 2.2 to determine the
‘Starting Point for Condensing for Simulated In-Line Systems.’
If using an in-line approach, skip
to step 5
.
NOTE: Contact the factory for approval when system design exceeds the guidelines set forth in the
table above. * Be sure to account for the runs where Tandem Tee Sets (P/N: V-TTS) are used in the system.
** Actual run; not calculated.
Design for Condensing Systems

13
HLV Series 2.0 Design •Design for Condensing Systems
4Measure the ‘Calculated Minimum Run’ for each burner. It is generally recommended to shorten
runs which exceed the ‘Calculated Maximum Run.’ Refer to Figures 2.2 and 2.3 on page 14 for
examples of determining ‘Calculated Maximum Run.’
5TEMPERATURE ZONES: In systems where dual zones will be used to control burners on
separate thermostats, the following guideline must be met:
a) Condensing pipe must begin at the point where two runs (operating on separate zones)
share common tubing and continue to the pump. See Figure 2.1.
6 Conrm the following applies (condensing systems only):
a) A maximum of three elbows per run is allowed per system.
b) A maximum of six intersections (tees or crosses) are allowed per system.
c) All elbows and intersections less than 20 feet from a burner requires a reector.
Figure 2.1 • Condensing Pipe for Dual Zone Systems and Simulated In-Line Burners
Points where zone 1 and 2 share
common tubing. Condensing
pipe must begin here.
Condensing Pipe
Tie-In BurnerTie-In Burner
T
Zone 1
T
Zone 2

14
HLV Series
2.0 Design •System Design Denitions
Sample Calculation:
Burner #1 = 30’ Single Flow
20’ / 2 = 10’ Common Flow
30’ + 10’ = 40’ Calculated Run
Calculated Maximum Run:
The longest allowable ‘Calculated Run’ from each burner to the vacuum pump, including condensing pipe.
Calculated Minimum Run:
The shortest allowable ‘Calculated Run’ from any burner (including P/N: V-TTS Tandem Tee runs) to the vacuum
pump, including condensing pipe.
Calculated Run ***read carefully***:
Calculated run is determined by adding the total ‘Single Flow’ plus one-half of the ‘Common Flow’ of tubing/
pipe from any burner to the vacuum pump.
Calculated Starting Point of Condensing Run:
The point in the ‘Calculated Run’ where condensing pipe must begin. See Figure 2.3.
Common Flow:
The tube/pipe in a run between the rst intersection (tee or cross) and the vacuum pump. ‘Common Flow’
begins at the point where two or more burners share common tube/pipe. See Figure 2.2.
Minimum Distance to Elbow or Intersection:
The minimum allowable distance from a burner to the rst elbow or intersection.
Run:
The total actual length of tube/pipe from an individual burner to the vacuum pump.
Single Flow:
The tube/pipe in a run from the burner to the rst intersection (tee or cross). See Figure 2.2.
Figure 2.2 • Single and Common Flow
Figure 2.3 • Starting Point of Condensing Pipe
Common Flow
Single Flow Single Flow
20 ft.
HLV-75
HLV-75
Vacuum Pump
30 ft. 30 ft.
HLV-75 HLV-75
Vacuum Pump
20 ft.
40 ft. 40 ft.
40 ft. Starting Point of Condensing
System Design Denitions
#1
#3 #4
#2

15
HLV Series 2.0 Design •Typical System Layouts
The following pages illustrate the most common system layouts and their applications. The layouts
shown are just a few of many possible designs. A particular application may call for a design that is
unique to match its particular building requirements. In any case, these layouts can serve as a
starting point for the design in many applications. NOTE: Figures 2.4 - 2.10 are provided for
illustrative purposes only and do not supersede any design parameters set forth in this manual. The
reectors have been intentionally omitted for easier viewing.
These layouts are commonly used for re stations, service garages, bus garages, arenas, and aircraft
hangars.
Figure 2.4 • Typical Layout A
This layout is typical in service garages,
warehouses, manufacturing plants,
greenhouses, and where even heat distribution
is a necessity.
Figure 2.5 • Typical Layout B
This layout is often used in small remote
bay areas or small service garage
apparatus bays.
Figure 2.6 • Typical Layout C
Typical System Layouts

16
HLV Series
2.0 Design •Typical System Layouts
These systems are comonly found in large buildings with long runs where roof penetrations are not desired.
They are normally designed for perimeter mounting such as indoor tracks, distribution centers, postal
centers, or aircraft hangars.
Figure 2.7 • Typical Layout D

17
HLV Series 2.0 Design •Typical System Layouts
This design is often used in service garages
where an oce or storage room exists.
Figure 2.9 • Typical Layout F
This design is often utilized in bus garages, large service garages, or large re stations where heaters should
run between the bays.
Figure 2.10 • Typical Layout G
Typically designed for warehouses, manufacturing
plants, or service garages.
Figure 2.8 • Typical Layout E

18
HLV Series
C
A
2.0 Design •Vacuum Pump Application
• The vacuum pump vent length must be between 2 ft. and 25 ft.
• The maximum number of elbows allowed in the vent system is two.
• Both isolation boots provided with the system must be installed prior to the vacuum pump (see
Figure 3.2 on page 21).
Vacuum pump selection is based on the overall BTU/h input of each system. Refer to Chart 2.3 for
vacuum pump determination. Note: The NC-7A vacuum pump can only be used on a non-
condensing design.
Example:
A system designed with one HLV-150 burner and two HLV-100 burners has a combined system
input of 350,000 BTU/h. This system requires a PB9 series vacuum pump as indicated in Chart
2.3.
Vacuum
Pump
Total System Input
Range (BTU/h)
Allowable Burners
per Pump Weight
Dimensions (See Figure 2.11)
A B C
NC-7A 40,000 to 150,000 1 min. / 2 max. 20 lbs. 10.0” 16.0” 18.5”
PB8 Series 50,000 to 275,000 1 min. / 4 max. 60 lbs. 11.0” 19.75” 16.5”
PB9 Series 280,000 to 545,000 2 min. / 5 max.* 67 lbs. 14.5” 19.75” 16.5”
PB10 Series 550,000 to 750,000 3 min. / 6 max.* 73 lbs. 17.5” 21.0” 20.0”
Chart 2.3 • Vacuum Pump Models
Figure 2.11 • Vacuum Pump Dimensions (see Chart 2.3)
B
C
B
NC-7A Pump - Side
View
NC-7A Pump - Front
View
PB Series Pumps - Isometric View
* Consult factory if installation requires exceeding maximum allowable burners.
NOTE: The average sound level of the PB series vacuum pumps is between 60 and 63 DBA. If the
application requires a lower decibel level, relocation of the vacuum pump or a sound-deadening
enclosure may be necessary. Consult the factory for assistance.
A
Vacuum Pump Application

19
HLV Series 2.0 Design •Damper Application
Figure 2.12 • Damper Placement - Equal Burner Inputs and Equal Tube Runs*
Figure 2.14 • Damper Placement - Equal Burner Inputs and Variable Tube Runs*
A primary damper is provided with every system and is placed before the vacuum pump.
Systems with variances in burner gas inputs and/or radiant tube runs will require the placement of
secondary dampers* to balance the system’s exhaust ow. NOTE: A maximum of six dampers are
allowed in a system. Refer to Figures 2.12 - 2.14 for examples of damper placement.
Figure 2.13 • Damper Placement - Variable Burner Inputs and Equal Tube Runs*
This system is comprised of two 75,000
BTU/h burners with equal lengths of
radiant tube running to the vacuum pump.
Only the primary damper is required in this
type of system.
HLV-75
Vacuum Pump
20 ft.
30 ft.
Primary Damper
(Sold with vacuum pump)
Primary Damper
(Sold with
vacuum pump)
Primary Damper
(Sold with
vacuum pump)
Isolation Boot
(Sold with vacuum
pump)
Isolation Boot
(Sold with vacuum pump)
Isolation Boot
(Sold with vacuum pump)
30 ft.
HLV-75
40 ft.
HLV-10 0
HLV-75
Vacuum Pump
20 ft.
40 ft.
Secondary Damper
(Sold as an accessory)
Secondary Damper
(Sold as an accessory)
40 ft. 30 ft.
Vacuum Pump
20 ft.
HLV-75
HLV-75
This system is comprised of two 75,000
BTU/h burners with unequal lengths of
tube run to the vacuum pump. The primary
damper is required at the vacuum pump
and a secondary damper is required prior
to the tee serving the shorter tube run.
A 75,000 BTU/h and a 100,000 BTU/h
burner with equal lengths of radiant tube
running to the vacuum pump make up this
system. The primary damper is required at
the vacuum pump and a secondary
damper is required prior to the tee serving
the lower BTU/h burner.
* In the event where a 40,000, 50,000 or 60,000 BTU/h burner shares a common run with a burner
greater than 75,000 BTU/h, each run must be dampered prior to each tee. This helps when
balancing the higher box pressure set points present on HLV-40, HLV-50 and HLV-60 burners.
Consult factory with any questions.
Damper Application

20
HLV Series
3.0 Installation
• Verify that the heater’s gas type and voltage (as listed on burner rating label) match that of the
application.
• Verify that all heater contents have been received by checking them against the packing list.
• Verify that the vacuum pump is adequate for the BTU/h input of the system (as listed on rating label).
• Identify the 10 ft. Alum-Ti combustion chamber(s) and ensure one exists per burner. These will be
installed as the rst tube section (welded seam down) immediately following each burner box.
• Following an engineered design layout, determine the location for the system’s suspension points in
relation to the building structure. Ensure that the installation will conform to the design
requirements listed in Sections 1.0 and 2.0 and clearances to combustibles (see Chart 1.2 on page 9)
will be maintained.
• Verify receipt of appropriate number of chains, gripple cable, and hangers used for suspending the
burner(s), radiant tubing, condensing pipe (if applicable) and reectors. See Figure 3.1.
NOTE: Mounting hardware must hang perpendicular to the system. The use of gripple cable (P/N:
THGHX) or 12 gauge, #1 double-loop chain (P/N: THCS) is recommended for hanging the system.
3.0 Installation •Pre-Installation
Figure 3.1 • Heater Suspension Points
WARNING
!
Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, serious injury, or death. Read and understand the installation,
operation, and maintenance instructions thoroughly before installing or servicing this
equipment. Only trained, qualied gas installation and service personnel may install or
service this equipment.
Not for residential use! Do not use this heater in the home, sleeping quarters,
attached garages, etc. Installation of a commercial tube heater system in
residential indoor spaces may result in property damage, serious injury, or death.
NOTE: A sticker identifying the combustion chamber(s)
is located on the swaged end of the tube(s).
10 ft. Titanium Treated (Alum-Ti)
Primary Combustion Chamber
Radiant Emitter Tube
NOTE: 150-200 MBH burners with the
hot-rolled steel option utilize an aluminized
steel secondary combustion chamber.
2’ 4”
8’ 10”
9’ 8” 9’ 8”
Burner
Control Box
Radiant Emitter Tube(s)
Suspension
Point
Burner Control Box
Suspension Points
Suspension Point
Suspension Point
Ignitor/Sensor Box
Stainless Steel Tube Clamp
(150-200 MBH burners only)
16” Burner
Tube
Pre-Installation