Mandik HELIOS Instructions for use

®
Installation,
operation instructions
and maintenance manual
Dark tube infrared heater
HELIOS
015/11
Revision 8 | Valid from 1. 1. 2022

Dark tube infrared heater HELIOS | Installation, operation instructions and maintenance manual.
2 |TP 015/11
CONTENT
I. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Infrared heater description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ordering key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Material, surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Data label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Logistic data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
II. INSTALLATION MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Suspension methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting components of infrared heater HELIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Instructions for assembling the body of the infrared heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement of the burner box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation of the exhaust box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flue exhaust – connection principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas connection installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
III. COMMISSIONING AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Commissioning conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Adjustment procedure of single-stage and two-stage heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjustment procedure of modulated heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Failure of infrared heaters HELIOS and their removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Conversion to another type of fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Recycling, dismantling after end of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Components used in infrared heaters HELIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
IV. CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Control of single-stage and two-stage heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Control of modulated infrared heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Temperature sensor placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

MANDÍK, a. s., Dobříšská 550, 267 24 Hostomice | www.mandik.cz TP 015/11 |3
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V. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Instructions for operating single-stage and two-stage infrared heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Instructions for operating modulated infrared heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
VI. DESIGN DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
VII. ECONOMIZER AWTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Economiser functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Economiser installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Economizer accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Dark tube infrared heater HELIOS | Installation, operation instructions and maintenance manual.
4 |TP 015/11
I. GENERAL
Dark tube infrared heater HELIOS (On/O), HELIOS D (two-stage) and HELIOS M
(modulated) in the performance series from 10 to 50 kW is a modern ecological
gas heater.
In terms of operating temperature of active surfaces and thus in
terms of the particular wavelength of the emitted radiation, the
device belongs to the category of so-called ”dark“ infrared heat-
ers. The active surface is formed by radiant pipes and a reector.
In the radiant pipes there is the process of fuel gas burning and
there are also burnt gases owing through the pipes to the mouth
of the exhaust fan. Fuel burning is carried out by an atmospheric
burner which is automatically controlled. The reector prevents the
pipes from cooling by the process of convection. The reector itself
warms up by the radiant pipes and radiates the heat in the required
direction.
Normal operating fuel of the HELIOS infrared heaters:
– natural gas – NG (G20/G25)
– propane – P (G31)
Product category:
– II2E3B/P
, II2ELL3B/P , design A2, B22, C12, C32, C62. NOXclass 3 (acc. EN 416-1/A1)
Infrared heaters HELIOS are intended for environment protected
against weather impacts with the classication of climatic condi-
tions class 3K5 acc. EN 60721-3-3 with temperature range from 0° to
35°C, for BNV premises acc. EN 1127-1. Installing infrared heaters as
design C is possible, except of normal spaces also in areas intended
for decommissioning and maintenance of vehicles. Such installation
must be assessed by the competent authorities in accordance with
the applicable regulations.,
Infrared heaters cannot be installed in individual, row and collective
garages, motor vehicle garages and operating rooms of fuel lling
stations with fuel dispensers. Infrared heaters cannot also be in-
stalled in places where there is a risk of re or explosion or high levels
of ammable dust.
Infrared heaters are suspended under the ceiling or on the walls in
the upper areas of the buildings so that the radiated beams point to
the oor towards the heated residential zone. The surfaces of oors,
walls, machines and other objects are heated by radiation and the
surrounding air is heated from them.
Infrared heater description
The infrared heater HELIOS consists of the following main parts:
– Burner box
– Exhaust box
– Reector with hinges and the radiant heating tubes ”U“ or ”I“
The basic design of the burner box is scalded by the throat for the
external suction in the upper part of the burner box. If the combus-
tion air supply system is not connected, it is an open gas appliance.
Thus, infrared heaters can only be used in a basic (normal) environ-
ment according to the according to the relevant standard. In order
to be considered as a closed gas appliance, the radiator must be
connected to outdoor air intake system.
Versions
According to power control of the burner, the infrared heaters
are single-stage I, U, LU, two-stage UD, LUD and modulating
UM, LUM.
Infrared heater with single-stage burner works in on-o mode.
Two-stage burner of the infrared heater operates in o mode
– reduced power – full power.
Modulated heater can vary the output as needed from minimum
to full.
The main advantages of the two-stage burner control include re-
ducing burner start-up frequency, better temperature distribution
in the heated space and reduced energy consumption. The mod-
ulated control of the burner is even more economical thanks to
asmooth change in performance.
Infrared heaters HELIOS are divided in terms of installation and
used reector:
– Ceiling infrared heaters with reectors tted with hinges in
version of hanging under the ceiling
– Wall infrared heaters with reectors tted with hinges
,,U(I)/15º, for hanging on the solid walls.
Reectors are supplied with thermal insulation, covered by a cover made of galvanized sheet metal.

MANDÍK, a. s., Dobříšská 550, 267 24 Hostomice | www.mandik.cz TP 015/11 |5
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Dimensions and weights
The weights of individual infrared heaters are given in Table 1. The weights of two-stage and modulated heaters (UD+, UD/15+, LUD+,
LUD/15+, UM+, UM/15+, LUM+, LUM/15+) are the same as the weights of single-stage heaters. The dimensions are visible from Fig. 1 to 4.
Tab. 1: Weights of the infrared heaters Helios
Type 20-I+ 30-I+ 40-I+
Weight [kg] 124.1 160.1 196.1
Type 20-I/15+ 30-I/15+ 40-I/15+
Weight [kg] 130.7 168.8 209.6
Type 10-U+ 20-U+ 30-U+ 40-U+
Weight [kg] 87 120 150.5 179.7
Type 10-U/15+ 20-U/15+ 30-U/15+ 40-U/15+
Weight [kg] 89.8 124.2 156 186.2
Type 20-LU+ 30-LU+ 40-LU+ 50-LU+
Weight [kg] 150.4 179.7 208.2 240.7
Type 20-LU/15+ 30-LU/15+ 40-LU/15+ 50-LU/15+
Weight [kg] 156 186.2 212.8 246.7
Fig. 1: Cross-section of the reector HELIOS 10 to 50-U, LU(D)+ Fig. 2: Průřez reektorem infrazářiče HELIOS 10 až 50-U, LU(D)/15+
Fig. 3: Cross-section of the reector HELIOS 20 to 40-I(D)+ Fig. 4: Cross-section of the reector HELIOS 20 to 40-I(D)/15+

Dark tube infrared heater HELIOS | Installation, operation instructions and maintenance manual.
6 |TP 015/11
Description of function
– Infrared heater operation is controlled by the automatics locat-
ed in the burner box, eventually by control board (models M).
– In case of single-stage or two-stage heater, after connecting
to the el. network, rst the basic test of the connected devic-
es to the automatic is performed and if everything is OK, the
exhaust fan is activated. Connecting the heater to the mains is
indicated by the green ”POWER“ light on the burner box.
– The modulated heaters are permanently connected to the
grid (the green ”POWER“ light on the burner box lights all the
time) and the radiator is waiting for a command to start. The au-
tomatics is connected to the power supply only after receiving
this command. Subsequently, the exhaust fan is started and
the next process is the same for all types of radiant heaters.
– After the fan starts and a vacuum is evoked in the burner cham-
ber, the dierential air manostat is switched. The manostat
senses the pressure dierential caused by the exhaust fan.
– When the manostat is switched on, the venting time (approx.
50 s) starts to run, this is used to ventilate the ue gas exhaust
pipe and heating tubes.
– After this ventilation time, the electromagnetic double valve is
opened and gas is injected into the burner. At the same time,
the ignition system is put into operation by the automatic
system.
– The ignition of the gas mixture in the burner is detected by the
ionisation electrode and simultaneously, the orange indicator
“FLAME”lights on.
– If the gas mixture in the burner is not ignited within 5sec-
onds, the valve closes the gas supply and the unburned gas/
air mixture is vented through the exhaust fan during the next
ventilation time. After it has elapsed, the automation runs two
more ignition cycles. If the heater fails to ignite, the red ”BURN-
ER FAILIURE“ indicator will light ON.
– Further start is possible after unlocking the fault condition. In
case of single-stage and two-stage heaters this is done by dis-
connecting and reconnecting to the power supply. For modu-
lated heaters, this state can be unblocked by disconnecting the
run request and reconnecting it. If this does not happen, the
modulated heater tries to unblock this state by itself and re-ig-
nite, but lengthens the intervals between individual attempts.
Ordering key
0 – without economiser
e2 – economiser 2 m
e4 – economiser 4 m
Gas
G20 natural gas Transit (ČR)
G25 natural gas Dutch (DE)
G31 propane
Tilt of the reector
15 – 15°
00 – 0°
Burner Control
D– Two-stage
J– Single-stage
Ma – modulated – analog
Mm – modulated – modbus
Heating tube shape
U, LU
I*
Performance series
10, 20, 30, 40, 50
HELIOS ×× × × × × ×G××– – – –
* Performance series only 20, 30, 40
EXAMPLE:
HELIOS 20-LUMa-00-G25-0 – 20 kW extended U-shaped analog modulated heater, without tilting, natural gas
HELIOS 30-UD-15-G31-e4 – 30 kW two-stage U-shaped heater, tilted, with economizer 4m, on propane

MANDÍK, a. s., Dobříšská 550, 267 24 Hostomice | www.mandik.cz TP 015/11 |7
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Material, surface treatment
Reectors of infrared heaters are made of aluminised sheet metal.
In insulated version they are equipped with thermal insulation from
mineral wool boards, covered with galvanized sheet. The hinges,
sockets and couplings are made of steel plates with heat-resist-
ant coating. The casing of the burner casing is made of galvanized
sheet steel, powder-coated on the outside. Radiant tubes are steel,
dark aluminised.
Data label
The type data label of the product is shown in Fig. 5.
Fig. 5: Type data label
Control
The equipment is checked and pre-set by the manufacturer, its operation depends on correct installation and adjustment.
Logistic data
Infrared heaters and its accessories are provided with packaging
foil and packed in cardboard boxes. They are transported with cov-
ered vehicles without the direct inuence of the weather. There
must be no vibration and the ambient temperature must not ex-
ceed +50 °C. When handling during transport and storage, infra-
red heaters and accessories must be protected against mechanical
damage. Infrared heaters must be stored in covered buildings, in
an environment free from aggressive vapours, gases and dust. The
delivery includes a complete HELIOS infrared radiator, enclosed
quality and completeness certicate with inspection stamp and
installation, operation and maintenance instructions.
If the method of acceptance is not specied in the order, handing
over the infrared heaters and accessories to the carrier will be con-
sidered as acceptance.

Dark tube infrared heater HELIOS | Installation, operation instructions and maintenance manual.
8 |TP 015/11
II. INSTALLATION MANUAL
Installation conditions
Before starting installation, make sure that local condition regard-
ing gas line, fuel and its pressure and heater setting are compatible.
Installation of the heater must be carried out in such way so that
an adequate space for servicing and adjustment is maintained (Fig.
10).
There must be ensured sucient air exchange in the building to al-
low for good combustion of gas. The amount of combustion air for
the infrared heaters must meet applicable standards. For installa-
tion of heaters in dusty environment, installation of duct supplying
the combustion air from outside (Closed appliance) is strongly rec-
ommended. The installation must comply with applicable stand-
ards and regulations and with this installation manual.
INSTALLATION OF THE INFRARED HEATER MAY BE DONE BY AUTHORIZED PERSON ONLY!
SURFACE TEMPERATURE OF THE RADIANT PIPE MAY EXCEED 500 °C!
Infrared heaters cannot be installed in places where there is a risk of re or explosion or high levels of ammable dust.
Using the heaters in a corrosive environment is prohibited!
Suspension methods
1. Dark tube infrared heaters can be suspended on suitable struc-
ture by means of chains or strings and snap-hooks or tie rods.
2. According to the Fig. 6 it is necessary to x the infrared heater
at least on two places by using an appropriate way so that the
device cannot be turned around.
3. Due to the thermal expansion, the infrared heater can not be
xed directly to the supporting structure.
4. It is necessary to keep safe distance from ammable objects
and walls (Fig. 7).
Fig. 6: Suspension of infrared heater Helios
Special cases of installation
When installing the heater over the runway of portal/bridge crane, it is necessary to use the protection of electrical power installation of
the crane against excessive heat. If installed in gyms, we recommend installation of safety grille – it can be ordered with the heater
from the manufacturer.

MANDÍK, a. s., Dobříšská 550, 267 24 Hostomice | www.mandik.cz TP 015/11 |9
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Fig. 7: Minimum safe distance of the infrared heater from walls, ceilings and ammable objects
Mounting components of infrared heater HELIOS
Individual assembly components of the infrared heater HELIOS:
– Burner box
– Exhaust (ventilation) box
– Connecting cable with connector
– Radiant tubes
– Tube connections, arch
– Hinges with xing clamps
– Reectors
– Arch cover
– Reector partitions
– Connecting material
Other components
(are not included in the infrared heater supply!):
– Remote control box, connecting cables
– Accessories, auxiliary fastening and connecting material
– Flue pipe or combustion air inlet pipeline

Dark tube infrared heater HELIOS | Installation, operation instructions and maintenance manual.
10 |TP 015/11
4 Hinge I – closed type
5 Hinge I – opened type
A Stainless-steel tube INOX 3,080 mm
B Stainless-steel tube INOX 1,580 mm
E Black tube 4595 mm – 1 socket
F Black tube 3090 mm – 1 socket
H Black tube 3290 mm – 1 socket
I Black tube 4595 mm – 2 sockets
K Black tube 6100 mm – 2 sockets
HELIOS 40 I HELIOS 30 I HELIOS 20 I
– Burner box
– Exhaust fan box
– Tennon joint with a clamb
Fig. 8: Scheme of infrared heaters Helios I+, ID+