BRANT RADIANT HLV User Manual

HLV Series Tube Heater

Vacuum System

Design, Installation, Operation and Maintenance Manual

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, reﬂector 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 ﬂoor level. This is how large spaces can be heated efﬁciently without having to provide primary infrared for every square foot of space.

For Your Safety

If you smell gas:

WARNING

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, ﬁre 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.

• 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 ﬁre department.

Keep these instructions for future reference.

LIOHLV-Rev. 21711

Print: 2M-8/13_r1-5/14(CDS)

Replaces: LIOHLV-2M-6/12(CDS)

Table of Contents

HLV Series

Contents

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

HLV Series Speciﬁcations ....................................................4

Approvals Standards and Certiﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Labels and Locations ..................................................6

Clearance to Combustibles ...................................................8

2.0 Design . . .....................................................................10

Pre-Design...............................................................10

Design for Non-Condensing Systems ..........................................11

Design for Condensing Systems ..............................................12

System Design Deﬁnitions...................................................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

Bafﬂe Assembly and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Reﬂector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Burner Assembly and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Flue Venting..............................................................31

Combustion Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Electrical Requirements.....................................................34

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Lighting and Shutdown .....................................................42

Sequence of Operation .....................................................42

Thermostat...............................................................43

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

System Start-Up Pre-Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Damper Adjustment ........................................................44

5.0 Maintenance ...................................................................45

Routine Inspection.........................................................45

Troubleshooting Guide......................................................46

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.0 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

HLV Series

1.0 Introduction • Overview • System Components

1.0 Introduction

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 (e.g., 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.

Figure 1.1 • Typical System Components*

* Each HLV Series vacuum system is engineered speciﬁc to each application’s design parameters. Some items illustrated may not be required with your system.

Tube H a ng er

Chain Set

Reﬂector End

Turnbuckle.

Burner Control Box

16” Burner Tube

Cap w/Clips

Reﬂector Center

Reﬂector Tension Spring

Tube Clamp

Support

Standard Reﬂector

Isolation Boot

Primary/Secondary

Combustion Chamber(s)

Radiant Tube (s)

Bafﬂes

SS Flex Connector

Damper

Ignitor/

Sensor Box

Vacuum Pump

Shut-off Valve

Refer to pages 50-51 for a complete parts breakdown.

1.0 Introduction • HLV Series Speciﬁcations

Speciﬁcations

Chart 1.1 • HLV Series Speciﬁcations

Approximate System

Hanging Weights

Burner Model

Gas

Types

BTU/H

(High Fire)

BTU/H

(Low Fire)

Per

Burner

Head

Per 10 Ft.

Radiant Pipe

& Reﬂector

Section

Per 10 Ft. Tailpipe & Reﬂector

Section

Typical

Mounting

Height^

Combustion

Chamber

(Black Coated)

Radiant

Emitter

Tube (s)* *

HLV Series

Condensing

Pipe

HLV- 40 *

HLV- 5 0*

HLV- 60

HLV-75

HLV- 80

HLV- 9 0

HLV-100

HLV-110

HLV-120

HLV-125

N or P

N or LP

N or P

40,000 40,000

50,000 50,000

60,000 50,000

75,000 60,000

80,000 64,000

90,000 72,000

100,000 80,000

110,000 88,000

120,000 96,000

125,000 100,000

35 lbs. 35 lbs. 45 lbs.

9’ to 14’

10’ to 15’

11’ to 18’

12’ to 20’

13’ to 23’

13’ to 25’

14’ to 27’

Al-Ti

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

HLV-140

HLV-150

HLV-170

HLV-175

HLV-180

HLV-20 0

N or P

140,000 112,000

150,000 120,000

170,000 136,000

175,000 140,000

180,000 144,000

200,000 160,000

35 lbs. 35 lbs. 45 lbs.

15’ to 30’

16’ to 40’

17’ to 42’

18’ to 47’

19’ to 50’

Al-Ti

Coated Alum or

Uncoated HRT

Coated Alum or

Uncoated HRT**

Coated Alum or

Uncoated HRT**

Coated Alum or

Uncoated HRT**

Coated Alum or

Uncoated HRT**

Coated Alum or

Uncoated HRT**

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

304 Stainless

Steel

* The HLV-40 and HLV-50 do not have a reduction for low ﬁre. ** 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-170, 175, 180 and 200 receive TP-220 stainless steel tube clamp.

HLV Series

1.0 Introduction • Approval Standards and Certiﬁcations • Applications

Approval Standards and Certiﬁcations

Installation of this tube heater must comply with all applicable local, state and national speciﬁcations, regulations and building codes. Contact the local building inspector and/or ﬁre Marshall 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 Z83.20b - American National Standards Institute.

• OSHA - Occupational Safety & Health Administration.

• CSA - Canadian Standards Association.

• Indoor approval.

Applications

WARNING

Not For Residential Use. Installation of a commercial tube heater system in residential indoor spaces

may result in property damage, serious injury or death.

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 Fire Marshall, insurance carrier and other authorities for approval if the proposed installation is in question.

Commercial/Industrial: Unless otherwise indicated, tube heaters are designed and certiﬁed for use in industrial and commercial 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 clearance

to combustibles (see pgs. 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. (2.4M) above the ﬂoor. 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, ofﬁces) the bottom of heaters shall be installed no less than 8 ft. (2.4M) above the ﬂoor.

• Suspended or elevated heaters shall be located in spaces where they shall not be subject to damage by aircraft, cranes, movable scaffolding or other objects.

High Altitude: Installation of this tube heater is approved, without modiﬁcations, for elevations up to 6,000 feet (1,829M) MSL (sea level) in the United States. Contact the factory for installations above these elevations.

1.0 Introduction • Safety Labels and Locations

HLV Series

Read and understand all safety information and warnings in this manual before installation, operation and maintenance of the radiant tube heater system.

Safety Labels and Their Locations

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 Z83.20b and CSA 2.34 requires you to post a sign near the heater’s thermostat, or 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 Limit Tag (F/N: LL01) is provided with each burner control box (see p.7). Contact Detroit Radiant Products Company or an authorized distributor for obtaining safety signs or replacement labels and tags.

Top Panel

HLV-40-125N

HLV-125

Production Code:

5.05

Version:

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:

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:

HEATER

TYPE:

For parts replacement information, contact factory at 586-756-0950 or visit www.drp-co.com/parts.

(Specify TP-#’s)

36G54-224-N 6465H 3 PCS Harness None None None None IS22016051F5169 Grey (+ / -)

SAMPLE

Norton High 4” Stnd. Yellow - 24V

Orifice Type: Gas:

TP-204#

Air:

1 1/2”

TP-44#31 5/8”

1540A 1251 3-PCS Harness N/A

N/A

264E

50 201B 380 828

C1 C2 C3

Serial No.: 0807XXXXXXXXXX 0001

None

Stock:

Add-On:

N/A

Red LED

Diag. Light:

None

Term. Block:

40 VA

Transformer:

Fasco Lg.

Fan:

50Hz - 120V

Alt. Fan:

When Specified

Alt. Fan Usage:

Picker x2

Relay:

None

Filter:

3 T-plug

24 Volt In:

2x4 Box

120 Volt In:

7/8” FC

Gas In:

None

Extra VL Orifice:

Internal Use Only:

Electric:

LLWT038

Tag:

1 5/8”

None

Special 1: Special 2:

F/N: LLTCL012 Clearance to

Combustibles Label.

827 N/A 826 55A 55B

1527 N/A 832 66 83

Burner Control Box

Component Label

1 7/16”

(located under the top panel)

Bottom Panel

F/N: LLLOGO1

HLV Series

- 120V HEATER INPUT -

Air Metering Orifice

DO NOT REMOVE

TP-114

TP-3014

3”

SAMPLE

1.0 Introduction • Safety Labels and Locations

F/N: LLAC Air Metering Oriﬁce

120V

F/ N: LLV3EP1

(Controls Compartment)

HOT

NEUTRAL

EARTH

Left Panel

Back Panel

HOT

NEUTRAL

120V

EARTH

- 120V HEATER INPUT -

RE-VERBER-RAY INFRA-RED RADIANT TUBE HEATER

FOR OUTDOOR USE AND INDOOR (Non-Residential) INSTALLATION ONLY. Class IIIA Permanent Label

MODEL NO.

HLV-40-125N

Volts AC:

120V - 60Hz

AMPS - Starting:

4.8

AMPS - Running:

1.1

Combustion Chamber:

4” Black Coated Aluminized

DESIGN COMPLIES WITH:

ANSI Z83.20b-2004-GAS FIRED LOW INTENSITY INFRA-RED HTR.

DETROIT RADIANT PRODUCTS COMPANY

21400 HOOVER ROAD - WARREN, MI (586) 756-0950 - www.drp-co.com

INPUT BTU/H

125,000 / 95,000

Manifold Pressure:

3.5 in.

Maximum Inlet Pressure:

14 in.

Minimum Inlet Pressure:

5.0 in.

SAMPLE

For stainless steel upgrades: The combustion tube is 409 Series stainless steel.

F/N: LLTB018 (Natural Gas) F/N: LLTB019 (LP Gas)

FOR USE WITH

Natural Gas

W.C.P.

Heater Type

Minimum Mounting Angle:

045DEGREES

Maximum Mounting Angle:

DEGREES

Serial No.: 0807XXXXXXXXXX 0001

Rating Plate

F/ N: LLV3EP2

Orange Crescent

Right Panel

(Valve Compartment)

F/N: LL01 - Clearance Safety Limit Tag (Afﬁx adjacent to heater’s thermostat)

16” Burner Tube

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.

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

F/N: LLV2EP9

Combustion Chamber

INSTALLER

F/ N: LLV2EP15

Radiant Tube

AVOID EQUIPMENT FAILURE

THIS 10 FT. TUBE IS THE

COMBUSTION CHAMBER.

The combustion chamber utilizes either 409 stainless, titanium alloy or aluminized steel -

depending on the model number of your heater.

THIS TUBE MUST BE THE FIRST TUBE

FOLLOWING THE BURNER CONTROL BOX.

Rotate the tube’s welded seam to bottom.

Consult the manual(s) for further details.

F/N: LLTB004 (orange)

1.0 Introduction • Clearance to Combustibles

HLV Series

Clearance to Combustibles

WARNING

Failure to maintain minimum clearance to combustibles may result in ﬁre 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.

Clearance to combustibles is deﬁned as the minimum distance that must exist between the tube surface, or reﬂector, 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 ﬁre Marshall, ﬁre insurance carrier or other qualiﬁed authorities on the installation and approval of the proposed installation.

WARNING

Placement of explosive objects, ﬂammable objects, liquids and vapors close to the heater may result in explosion, ﬁre, property damage, serious injury or death. Do not store or use explosive objects, liquids or vapor in the vicinity of the heater.

Clearances listed in Chart 1.2 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 thermostats or, in the absence of such thermostats, in a conspicuous location.

The stated clearance to combustibles represents a surface temperature of 90°F (32°C) above room temperature. Building materials 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.

Figure 1.2 • Mounting Angles

0° Mounting Angle

with 2 Side Shields

(P/N: SSE)

Top

0° Mounting Angle 45° Mounting Angle

Top

0° Mounting Angle

with 1 Side Shield

(P/N: SSE)

Top

Side

Below

Side

Front

Below

Behind

Front Behind

Below

Side Side

Below

HLV Series

1.0 Introduction • Clearance to Combustibles

Chart 1.2 • Clearance to Combustibles in Inches (see Figure 1.2 for Mounting Angles)

Mounting

Model Number

HLV-40, HLV-50 [N, P]

with 1 side shield 0° 29 8 4 47 with 2 side shields 0° 9 9 4 47 20 ft. from burner 0° 7 7 4 30

HLV-60, HLV-75 [N, P]

with 1 side shield 0° 29 8 4 48 with 2 side shields 0° 9 9 4 48 20 ft. from burner 0° 7 7 4 30

HLV-80 [N, P]

with 1 side shield 0° 29 8 4 48 with 2 side shields 0° 16 16 4 48 20 ft. from burner 0° 7 7 4 30

HLV-90 [N, P]

with 1 side shield 0° 29 8 4 54 with 2 side shields 0° 16 16 4 54 20 ft. from burner 0° 7 7 4 30

HLV-100 [N, P]

with 1 side shield 0° 29 8 4 66 with 2 side shields 0° 16 16 4 66 20 ft. from burner 0° 7 7 4 30

HLV-110, HLV-120, HLV-125 [N, P]

with 1 side shield 0° 42 8 4 72 with 2 side shields 0° 20 20 4 72 20 ft. from burner 0° 7 7 4

HLV-140, HLV-150 [N, P]

with 1 side shield 0° 42 8 6 81 with 2 side shields 0° 30 30 6 81 20 ft. from burner 0° 11 11 6 44

HLV-170, HLV-175 [N, P]

with 1 side shield 0° 50 8 6 92 with 2 side shields 0° 30 30 6 92 20 ft. from burner 0° 11 11 6 44

HLV-180, HLV-200 [N, P]

with 1 side shield 0° 54 8 6 94 with 2 side shields 0° 30 30 6 94 20 ft. from burner 0° 11 11 6 44

Heaters mounted on an angle between 0° to 45° must maintain clearances posted for 0° or 45°; whichever is greater.

The top clearance of an exposed tube connection to combustibles is 18 inches.

Angle*

0° 9 9 4 47

45° 39 8 10 47

0° 9 9 4 48

45° 39 8 10 48

0° 11 11 4 48

45° 39 8 10 48

0° 12 12 4 54

45° 39 8 10 54

0° 14 14 4 66

45° 39 8 10 66

0° 18 18 4 72

45° 58 8 10 72

0° 24 24 6 81

45° 58 8 10 81

0° 34 34 6 92

45° 63 8 10 92

0° 41 41 6 94

45° 63 8 10 94

Front Behind Top** Below

Sides

2.0 Design • Pre-Design

HLV Series

2.0 Design

Pre-Design for Condensing and Non-Condensing Systems

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 it is uncertain as to what type of system should be used, begin by designing for a condensing system, p.12. If the completed design does not require condensing pipe then, by default, the system will become a non-condensing system.

1 Most non-condensing systems should be controlled via a single temperature zone. If two zones are

required, it may be necessary (in most cases) that the system be designed as a condensing system (p.12). Contact factory for additional guidelines.

2 Determine the heat load requirement of the building.

3 Available mounting heights and coverage are the two most critical variables in burner selection and

quantity.

• The mounting height of the system determines the largest burner model that can be used.

• As the design is calculated, and if it is discovered that the quantity of burners in the system will not provide sufﬁcient coverage, it may be necessary to use a larger quantity of lower input burners.

4 When determining system location, clearance 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, p.9 for Clearance to Combustibles distances.

IMPORTANT: Fire sprinkler heads must be located at an appropriate distance from the heater. This distance may exceed the published clearance 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 ﬂammable substances are not to be used in conjunction with this heater without careful consideration for and avoidance of potential ﬁre or explosion hazards. For further information consult NFPA 13.

5 Reference p.14 for System Design Deﬁnitions.

HLV Series

2.0 Design • Design for Non-Condensing Systems

Design for Non-Condensing Systems

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 ﬁttings as they have been accounted for.

Designing a non-condensing system can be fairly straightforward given the following steps are read carefully. In addition to these steps, an understanding of the design deﬁnitions is critical. Refer to p.14 for these terms and illustrations.

1 Begin 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, conﬁrm 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 Conﬁrm 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 reﬂector.

Chart 2.1 • Design Parameters for Non-Condensing Systems (refer to page 14 for deﬁnitions).

Minimum Distance from Burner to First Elbow or

HLV Burner Model

HLV- 40 , H LV- 5 0 , H LV- 6 0

HLV-75, HLV- 80

HLV- 90 , HLV-100

HLV-110, HLV-120, HLV-12 5

HLV-140, HLV-150

HLV-170, H LV-175 , H LV-180

HLV-2 0 0

Intersection

10 ft. 30 ft. 60 ft.

10 ft. 35 ft. 65 ft.

10 ft. 40 ft. 70 ft.

10 ft. 45 ft. 75 ft.

15 f t. 50 ft. 80 ft.

15 f t. 55 ft. 85 ft.

20 ft. 60 ft. 90 ft.

* Be sure to account for runs where Tandem Tee Set (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.

Calculated

Minimum Run*

Calculated

Maximum Run*

2.0 Design • Design for Condensing Systems

HLV Series

Design for Condensing Systems

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 ﬁttings as they have been accounted for.

Designing a condensing system can be fairly straightforward given the following steps are read carefully. In addition to these steps, an understanding of the design deﬁnitions is critical. Refer to p.14 for these terms and illustrations.

1 Begin 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, conﬁrm 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.

3 Refer 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 regarded as 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’.

skip to step 5

Chart 2.2 • Design Parameters for Condensing Systems (refer to page 14 for deﬁnitions).

HLV Burner

Model

40, 50, 60

75, 80

90, 100

Minimum

Distance from

Burner to First

Elbow or

Intersection (Ft.)

10 30 60 175 50 40

10 35 65 200 55 50

10 40 70 200 60 50

Calculated

Minimum

Run (Ft.)**

Calculated

Starting Point

of Condensing

Run (Ft.)

Calculated

Maximum Run

(Including

Condensing

Pipe) (Ft.)

When using an in-line approach,

Simulated In-Line Systems*

Starting Point

Maximum Actual

Distance Between Tie-Ins for Simulated In-Line Systems (Ft.)

(after last tie-in)

for Condensing for

Simulated In-Line

Systems (Ft.) .

110, 120, 125

140, 150

170, 175, 180

200

10 45 75 225 65 60

15 50 80 225 70 60

15 55 85 250 75 70

20 60 90 250 80 70

NOTE: Contact the factory for approval when system design exceeds the guidelines set forth in the table above.

used in the system.

* Actual run; not calculated. **Be sure to account for runs where Tandem Tee Set (V-TTS) are

HLV Series

2.0 Design • Design for Condensing Systems

4 Measure 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 & 2.3 on p.14 for examples of determining ‘Calculated Maximum Run’.

5 TEMPERATURE 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; continuing to the pump. See Figure 2.1.

6 Conﬁrm 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 reﬂector.

Figure 2.1 • Condensing Pipe for Dual Zone Systems and Simulated In-Line Burners

Zone 1

Condensing Pipe

Points where zone 1 & 2 share

common tubing. Condensing

pipe must begin here.

Condensing Pipe

Zone 2

Tie-In Burner

2.0 Design • System Design Deﬁnitions

HLV Series

System Design Deﬁnitions

Calculated Maximum Run:

The longest allowable ‘Calculated Run’ from any burner to the vacuum pump, including condensing pipe.

Calculated Minimum Run:

The shortest allowable ‘Calculated Run’ from any burner (including 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 ﬁrst 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 ﬁrst 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 ﬁrst intersection (tee or cross). See Figure 2.3.

Figure 2.2 • Single and Common Flow

Vacuum Pump

20 ft.

HLV-7 5

Single Flow Single Flow

30 ft. 30 ft.

Common Flow

HLV-7 5

Figure 2.3 • Starting Point of Condensing Pipe

40 ft. 40 ft.

HLV-7 5 HLV-7 5

40 ft.

Starting Point of Condensing

20 ft.

Vacuum Pump

HLV Series

2.0 Design • Typical System Layouts

Typical System Layouts

The following pages illustrate the most common system layouts and their applications. The layouts shown are just a few of many designs. A particular application may call for a design that is unique to match its’ particular building requirements. In any case, these layouts should serve as a starting point for the design in many applications. NOTE: Figures 2.4 - 2.10 are provided for illustrative purposes only and must not supersede any design parameters set forth in this manual.

Figure 2.4 • Typical Layout A

These layouts are typically designed for ﬁre stations, service garages, bus garages, arenas and aircraft hangars.

Figure 2.5 • Typical Layout B

This layout is typical in service garages, warehouses, manufacturing plants, greenhouses and where even heat distribution is a necessity.

Figure 2.6 • Typical Layout C

This layout is for use in small remote bay areas or small service garage apparatus bays.

2.0 Design • Typical System Layouts

HLV Series

Figure 2.7 • Typical Layout D

These systems are typically found in large buildings with long runs where roof penetrations are not desired. These layouts are normally designed for perimeter mounting such as indoor tracks, distribution centers, postal centers or aircraft hangars.

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