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7D851A
User Manual
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Dayton 7D851A, 7AR79, 7AR88, 7D849A, 7D837A User Manual

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Installation, Operation, Maintenance and Parts Manual
7D837A thru 7D849A, 7D851A,
7AR79 thru 7AR88
®
Dayton Tube Heaters
Description
Dayton tube heaters are gas-fired infrared heaters designed to provide comfort heat. They consist of three (3) main components: a burner control box, radiant tube, and reflector assembly. The heaters are typically suspended from the ceiling by chains and controlled by a thermostat. They can be installed either vented or unvented, and may use outside air for combustion if necessary. The radiant tube may be installed in different configurations depending on the heating requirements.
These heaters use infrared energy to heat spaces. When heat is required, the burner control box ignites a gas/air mixture and pushes the hot gases into the radiant tube. As the gases pass through the assembly, the tubing is heated and emits infrared, which is then directed toward the floor by reflectors. This is known as primary infrared and is absorbed by the floor, objects and people in the space, raising their temperatures. They in turn re-radiate this heat, known as secondary infrared, to create a comfort zone at the floor level. This is how Dayton tube heaters can heat large spaces without having to provide primary infrared for every square foot of area. However, if the goal is to spot heat a small area within a large space, only the primary infrared makes this possible. Dayton tube heaters are design certified for use in industrial and commercial buildings, such as warehouses, manufacturing plants, aircraft hangars and vehicle maintenance shops. They are not certified for residential use or where flammable gases or vapors are generally present, such as spray booths.
damage, injury or death. Read and understand the installation, operating 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 and/ or property damage.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property
For Your Safety - If you smell gas:
WARNING
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.
Form 5S6496 Printed in U.S.A.
03460 1109/224/VCPVP
• 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.
Dayton Installation, Operation, Maintenance and Parts Manual
®
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Dayton Tube Heaters
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................................... 3
Overview ........................................................................................................................................................................ 3
SAFETY .............................................................................................................................................................................. 4
Warning Symbols ............................................................................................................................................................ 4
Specific Applications ....................................................................................................................................................... 4
Standards, Certifications and Governmental Regulations ................................................................................................ 5
Clearance to Combustibles ............................................................................................................................................ 6
INSTALLATION ..................................................................................................................................................................... 8
Design Considerations and Prechecks .............................................................................................................................. 8
Recommended Mounting Heights ................................................................................................................................... 10
Hanger Placement and Suspension ..................................................................................................................................11
Optional U-Bend or Elbow Accessory Configuration ........................................................................................................ 14
Radiant Tube Assembly ................................................................................................................................................... 15
Burner Control Box Suspension ...................................................................................................................................... 18
Reflector Assembly ..........................................................................................................................................................19
Baffle Assembly and Placement ....................................................................................................................................... 21
Final Heater Assembly ..................................................................................................................................................... 22
Venting ...........................................................................................................................................................................23
Combustion Air Requirements ........................................................................................................................................28
Gas Supply .....................................................................................................................................................................30
Electrical Requirements ................................................................................................................................................... 33
OPERATION ..........................................................................................................................................................................35
MAINTENANCE ...................................................................................................................................................................36
Troubleshooting Guide ....................................................................................................................................................37
PARTS ..............................................................................................................................................................................38
Repair Parts Illustration ....................................................................................................................................................38
Repair Parts List ...............................................................................................................................................................39
LIMITED WARRANTY .......................................................................................................................................................... 40
Kit Contents
Prior to installation, verify that you have received all heater components included with your tube heater. Refer to the chart below for a list of the kit contents for your model heater. Materials not included in the kit (e.g. sheet metal screws, vent material, terminals, etc.) are the responsibility of the installer.
Filled By:
5VD67A-
5VD70A
5VD71A-
5VD72A
5VD73A-
5VD78A
5EAJ0-J2,
5EAH3-H5
5VD79A-80A,
5EAH6-H8
Part # Description 20 ft. 30 ft. 40ft. 50ft. 60ft.
TP-19B 4” Tube Hanger with Tension Spring 3 4 5 6 7 TP-21B 4” Tube Clamp 2 3 4 5 6 TP-33B 1/2” Shut-off Ball Valve/Inlet Tap 1 1 1 1 1 TP-82 4” Reflector Center Support 2 3 4 5 6 TP-83 24” Stainless Steel Flexible Gas Connector 1 1 1 1 1 TP-105 Reflector End Cap 2 2 2 2 2 TP-106 Reflector End Cap Clips 8 8 8 8 8 THCS Tube Heater Chain Sets 5 6 7 8 9 IOM Installation, Operation & Maintenance Manual 1 1 1 1 1
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Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
INTRODUCTION
Overview
The intent of this manual is to provide information regarding general safety, installation, operation and maintenance of this tube heater. You must read and understand all instructions and safety warnings before installing or servicing the tube heater.
Available Models - Tube Heater Burner Box and Tube Reflector Combinations
Burner
Combo #
7D837A 5VD67A 5VD88 20-4”-ALUM 20 50,000 NAT
7D838A 5VD68A 5VD88 20-4”-ALUM 20 50,000 LP
7D839A 5VD69A 5VD88 20-4”-ALUM 20 75,000 NAT
7D840A 5VD70A 5VD88 20-4”-ALUM 20 75,000 LP
7D841A 5VD71A 5VD89 30-4”-ALUM 30 100,000 NAT
7D842A 5VD72A 5VD89 30-4”-ALUM 30 100,000 LP
7D843A 5VD73A 5VD91 40-4”-ALUM 40 100,000 NAT
7D844A 5VD74A 5VD91 40-4”-ALUM 40 100,000 LP
7D845A 5VD75A 5VD91 40-4”-ALUM 40 125,000 NAT
7D846A 5VD76A 5VD91 40-4”-ALUM 40 125,000 LP
7D847A 5VD77A 5VD90 40-4”-TITAN 40 150,000 NAT
7D848A 5VD78A 5VD90 40-4”-TITAN 40 150,000 LP
7AR80 5EAJ0 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 150,000 NAT
7AR79 5EAJ1 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 150,000 LP
7AR83 5EAJ2 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 175,000 NAT
Box #
Tube &
Reflector Pkg # Tube Type Length BTU/H Gas Type
7AR81 5EAH3 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 175,000 LP
7AR87 5EAH4 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 200,000 NAT
7AR85 5EAH5 5VD90 & 5EAH2 40-4”-TITAN & 10-4”-ALUM 50 200,000 LP
7D849A 5VD79A 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 150,000 NAT
7D851A 5VD80A 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 150,000 LP
7AR84 5EAH6 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 175,000 NAT
7AR82 5EAH7 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 175,000 LP
7AR88 5EAH8 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 200,000 NAT
7AR86 5EAH9 5VD90 & 5VD88 40-4”-TITAN & 20-4”-ALUM 60 200,000 LP
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
SAFETY
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
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WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, serious injury or death. Read and understand, the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment. Only trained, qualified gas installation
and service personnel may install or service this equipment.
Safety Symbols
Safety is the most important consideration during installation, operation and maintenance of the tube heater. You will see the following symbols and signal words when there is a hazard related to safety or property damage.
Applications
WARNING
Warning indicates a potentially
hazardous situation which, if not avoided, could result in death or injury.
This is not an explosion-proof heater. No heater may be used in a Class 1 or Class 2 Explosive Environment. Consult the local Fire Marshall, fire insurance carrier and other authorities for approval if the proposed installation is in question.
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WARNING
Not for residential use!
Do not use this heater in the home, sleeping quarters, attached garages, etc.
Commercial and Industrial
This tube heater is designed and certified for use in industrial and commercial buildings such as, warehouses, manufacturing plants, aircraft hangars and vehicle maintenance shops.
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CAUTION
Caution indicates a potentially
hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Notice indicates a potentially hazardous situation which, if not avoided, could result in property damage.
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Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Standards, Certifications and Governmental Regulations
The 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) before installing the heater system.
In the absence of local codes, the installation must conform to the latest edition of the National Fuel Code ANSI Z223.1 (NFPA 54).
Refer to the following Standards and codes for application specific guidelines:
Public Garages:
The installation of this heater in public garages must conform with the Standard for Parking Structures, ANSI/ NFPA 88A (latest edition), or the Code for Motor Fuel Dispensing Facilities and Repair Garages NFPA 30A (latest edition) and must be at least 8 ft. above the floor.
Aircraft Hangars:
The installation of this heater in aircraft hangars must conform with the Standard for Aircraft Hangars, ANSI/ NFPA 409 (latest edition). The heater must be installed at least 10 ft. above the upper wing surfaces and engine enclosures of the highest aircraft which might be stored in the hangar. In areas adjoining the aircraft storage area, the heaters must be installed at least 8 ft. above the floor. The heaters must be located in areas where they will not be subject to damage by aircraft, cranes, moveable scaffolding or other objects.
High Altitude:
The installation of this tube heater is approved, without modifications, for elevations up to 6,000 ft. MSL (sea level). Contact Dayton for installations above these elevations.
Electrical:
The heater, when installed, must be electrically grounded in accordance with the National Electrical Code ANSI/NFPA 70 (latest edition). Under no circumstances is either the electrical supply line or gas supply line to provide any assistance in the suspension of the heater.
Venting:
Venting must be installed in accordance with the requirements set forth in this manual and with the NFPA 54/ANSI Z223.1 National Fuel Gas Code (latest edition).
This unit complies with or is Certified by one or more of the following organizations or Standards:
• CSA International (CSA).
• American National Standards (ANSI Z83.20b).
• National Fuel Gas Code (NFPA 54/ ANSI Z223.1).
• Occupational Safety and Health Act (OSHA).
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Dayton Installation, Operation, Maintenance and Parts Manual
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Dayton Tube Heaters
Clearance to Combustibles
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
WARNING
This is not an explosion-proof heater. Do not store or use
flammable objects, liquids or vapor in the vicinity of the heater. Where there is the possibility of exposure to flammable vapors or highly combustible materials, consult the local fire marshall, fire insurance carrier and other authorities for approval of the proposed installation.
Hazards
For maximum safety, the building must be evaluated for hazards before installing this heating system. A critical safety factor before installation is the clearance to combustibles.
Clearances to combustibles is defined as the minimum distance that must be maintained between the tube surface or reflector and combustible materials. It also pertains to the distance that must be maintained from moving objects (e.g. overhead doors, cranes, vehicle lifts, etc.) around the tube heater.
WARNING
This heater should be installed so that the minimum clearances to combustibles,
as marked on the heater, will be maintained from vehicles parked below. If vehicle lifts are present, ensure that these clearances will be maintained from vehicles parked below. If vehicle lifts are present, ensure that these clearances will be maintained from the highest raised vehicle.
The following is a partial list of items to maintain clearances from:
• Gas and electrical lines
• Combustible and explosive materials
• Chemical storage areas
• Areas of high chemical fume concentrations
• Vehicle parking areas
• Vehicle lifts
• Hoists or cranes
• Storage areas with stacked materials
• Lighting
• Sprinkler heads
• Overhead doors and tracks
• Dirty, contaminated areas
WARNING
Fire Hazard. Always
maintain published clearance to combustibles. Failure
to comply with the stated clearances to combustibles could result in personal injury, death and/or property damage.
If you are unsure about the proposed installation, consult your local fire Marshall, fire insurance carrier or other qualified authorities for the approval of the proposed installation.
Safety Signs and Labels
It is important to provide warnings to alert individuals to potential hazards and safety actions. ANSI Z83.20b and CSA 2.34, require you to post a sign “specifying the maximum permissible stacking height to maintain the required published clearances from the heater to combustibles” near the heater’s thermostat or, in the absence of such thermostats, in a conspicuous location.
All safety labels must be maintained on this appliance. Contact Grainger if replacement labels are needed.
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Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Clearance to Combustibles
For the safe installation of this unit, the clearance to combustibles data below (Figure 1.1) contains clearances that must be maintained. Check the heater’s rating plate to verify the minimum clearance to combustibles and gas type for your model heater.
Figure 1.1 • Clearances to Combustibles Data
0° Mounting Angle
Side
45° Mounting Angle
Front
0° w/ 1 Side Shield
Front
0° W/ 2 Side Shields
Side
Top
Side
Below
Top
Behind
Below
Top
Behind
Below
Top
Side
Below
Mounting
Model No.
Dayton - 5VD67A, 5VD68A (20’ min. to 40’ max.) 50,000 BTU/H [N, P]
7D - 837A,838A 0° w/ 1 side shield 0° 29 8 6 47 0° w/ 2 side shields 0° 9 9 6 47 20 ft. from burner 0° 7 7 6 30
Dayton - 5VD69A, 5VD70A (20’ min. to 40’ max.) 75,000 BTU/H [N, P]
7D - 839A,840A 0° w/ 1 side shield 0° 29 8 6 60 0° w/ 2 side shields 0° 9 9 6 60 20 ft. from burner 0° 7 7 6 30
Dayton - 5VD71A, 5VD72A, 5VD73A, 5VD74A (30’ min. to 40’ max.) 100,000 BTU/H [N, P]
7D - 841A,842A,843A,844A 0° w/ 1 side shield 0° 29 8 6 66 0° w/ 2 side shields 0° 16 16 6 66 20 ft. from burner 0° 7 7 6 30
Dayton - 5VD75A, 5VD76A (40’ min. to 60’ max.) 125,000 BTU/H [N, P]
7D - 845A,846A 0° w/ 1 side shield 0° 42 8 6 76 0° w/ 2 side shields 0° 20 20 6 76 20 ft. from burner 0° 7 11 6 30
Dayton - 5VD77A, 5VD78A, 5VD79A, 5VD80A, 5EAJ0, 5EAJ1 (40’ min. to 60’ max.) 150,000 BTU/H [N, P]
7D-847A,848A,849A,851A, 7AR-79,80 0° w/ 1 side shield 0° 42 8 6 81 0° w/ 2 side shields 0° 23 23 6 81 20 ft. from burner 0° 11 11 6 44
Dayton - 5EAJ2, 5EAH3, 5EAH6, 5EAH7 (50’ min. to 60’ max.) 175,000 BTU/H [N, P]
7AR - 81, 82, 83, 84 0° w/ 1 side shield 0° 50 8 6 92 0° w/ 2 side shields 0° 30 30 6 92 20 ft. from burner 0° 11 11 6 44
Dayton - 5EAH4, 5EAH5, 5EAH8, 5EAH9 (50’ min. to 60’ max.) 200,000 BTU/H [N, P]
7AR - 85, 86, 87, 88 0° w/ 1 side shield 0° 54 8 6 94 0° w/ 2 side shields 0° 30 30 6 94
20 ft. from burner 0° 11 11 6 44 Minimum end clearance for all models is 12 inches. *Heaters mounted on an angle between 0° to 45° must maintain clearances posted for both 0° and 45° mounting angles; whichever is greater.
Angle *
0° 9 9 6 47
45° 39 8 10 47
0° 9 9 6 60
45° 39 8 10 60
0° 14 14 6 66
45° 39 8 10 66
0° 20 20 6 76
45° 58 8 10 76
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
Side
Top BelowFront Behind
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Installation
Design Considerations and Prechecks
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Placement of infrared tube heaters is influenced by many factors. Aside from safety factors, considerations such as the number of elbows that are allowed, maximum vent lengths, ducting of combustion air and combining vents are a few examples. This manual, along with national, state
and local codes, addresses these issues. It is critical that all guidelines and instructions are followed.
To ensure a properly designed heating system, a heating layout should be developed for the correct placement of the burner control box, radiant
tubing, venting and combustion air intake ducts. Inspect and evaluate the mounting conditions, vent locations, gas supply and electrical wiring. Refer to the chart below for the recommended distances for the model being installed.
Heater Installation Chart
Distance
Recommended
Model # BTU/H
7D837A-7D838A 50,000 9’ to 14’ 10’ to 20’ 20’ to 40’ 16’
7D839A-7D840A 75,000 11’ to 18’ 20’ to 30’ 30’ to 50’ 20’
7D841A-7D844A 100,000 13’ to 23’ 20’ to 30’ 30’ to 50’ 20’
7D845A-7D846A 125,000 14’ to 25’ 20’ to 30’ 30’ to 50’ 25’
7D847A-7D851A, 7AR79-7AR80
7AR81-7AR84 175,000 17’ to 35’ 30’ to 40’ 40’ to 60’ 30’
7AR85-7AR88 200,000 18’ to 40’ 30’ to 40’ 40’ to 60’ 30’
150,000 15’ to 35’ 30’ to 40’ 40’ to 60’ 25’
Mounting Heights
Between
Heaters
Distance
Between
Heater Rows
Maximum
Distance Between
Heater and Wall
When designing an infrared radiant heating system, consider the following:
• Has the building’s heat loss been evaluated?
• Does the design meet the needs of the space?
• Have all clearance to combustible situations been observed?
• Have recommended mounting heights been observed?
• Is the supply (burner) end of the heater located where more heat is required?
• Is it best to offset the heaters and/ or rotate the reflectors towards the heat zone?
• Are protective guards, side shields, ‘U’ or ‘L’ reflector covers needed?
• Does the heater require outside fresh air for combustion?
• Is the environment harsh or contaminated (requiring outside air for combustion)?
• Are chemicals or vapor a concern (requiring outside air for combustion)?
NOTE: The effective infrared surface temperature of a person or object may be diminished with wind above 5 mph. The use of adequate wind barrier(s) may be required.
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NOTE: When heated, materials high in hydrocarbons (solvents, paint thinner, mineral spirits, formaldehydes, etc.) can evaporate. This may result in odors or fumes being emitted into the environment. To correct this problem, clean the area and/or introduce additional ventilation.
Heaters installed and serviced in accordance with the installation manual do not emit odors into the environment. See notice on page 28 additional information.
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Design Scenario
A tube heater system is being installed in 70’ (L) x 40’ (W) space with 12’ ceilings. Two overhead doors are located at one end and an equipment storage area exists on one side. The calculated heat load is 300,000 BTU/H.
Figure 2.1 • Poor Design
• Two burners (150,000 BTU/H each) are placed at one end, opposite the area of highest demand (overhead doors).
• Recommended mounting heights are not observed.
• Produces an uneven heat distribution.
Figure 2.2 • Good Design
• Four burners (75,000 BTU/H each) are placed in each corner. Burner (hotter) ends direct heat to areas of highest head demand.
• Recommended mounting heights observed.
Doors and
tracks
Too Cold
Doors and
tracks
Doors and
tracks
70’
60’ - 150,000 BTU
Equipment storage
Poor Design
70’
20’ - 75,000 BTU
Equipment storage
Better Heat Distribution
Gas Supply
(2 total)
Too Hot
Gas Supply
(4 total)
40’
40’
• Distributes heat more evenly.
Good Design
Doors and
tracks
Sidewall Vent (2 total)
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Recommended Mounting Heights
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Model
20 ft. 50 MBH 10’ - 16’ 20’ x 12’ 12’ x 12’ 10’ - 20’ 20’ - 40’ 16’
30 ft. 100 MBH 13’ - 20’ 33’ x 18’ N/A 20’ - 30’ 30’ - 50’ 20’
40 ft. 100-125 MBH 13’ - 25’ 44’ x 21’ 23’ x 17’ 20’ - 30’ 30’ - 50’ 20’
50 ft.
60 ft.
NOTE: Factory recommended mounting heights are listed as a guideline. If infrared heaters are mounted to low or to high, they may result in heat discomfort or lack of heat. It is generally recommended to
Figure 2.3 • Recommended Mounting Heights and Distances - see chart above for dimensions.
150-200 MBH 16’ - 30’ 56’ x 30’ N/A 30’ - 40’ 40’ - 60’ 25’
150-200 MBH 17’ - 40’ 67’ x 34’ 34’ x 26’ 30’ - 40’ 40’ - 60’ 25’
BTU Range
75 MBH 12’ - 20’ 22’ x 15’ 12’ x 12’ 20’ - 30’ 30’ - 50’ 18’
150 MBH 16’ - 30’ 45’ x 26’ 24’ x 20’ 30’ - 40’ 40’ - 60’ 25’
Recommended
Mounting Heights
observe the recommended mounting heights to optimize comfort conditions. However, certain applications such as spot heating, freeze protection, outdoor patio heating or very high ceilings may result in the heaters
Coverage Straight
Config. (LxW)
Coverage U-Tube
Config. (LxW)
Distance Between
Heater Rows (Ft.)
Dim. A
being mounted outside of the factory recommended mounting heights. Clearances to combustibles must always be maintained.
Distance Between
Heater Rows (Ft.)
Dim. B
Max. Distance Be-
tween Heaters and
Wall (Ft.)
Dim C
Dimension B
Distance between heater rows
Dimension C
Maximum distance between heater and wall
Dimension A
Dimension A
10
Dimension C
Maximum
distance
between
heater
and wall
Dayton Installation, Operation, Maintenance and Parts Manual
!
!
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Hanger Placement and Suspension
Suspension of the heater must conform to applicable codes referenced in the Safety section and these instructions.
1. Lay radiant tubing out in the following order. Position tubes in their approximate locations. Figure
2.4.
• 10 ft. primary combustion chamber.
• Radiant emitter tubes.
IMPORTANT! 150 MBH models must use the 10 ft. titanium alloy treated combustion chamber as the first tube connected to the burner control box. The combustion chamber has an orange identification sticker located on the swaged end of the tube.
2. Mark locations for hanging points. Figure 2.4 Chart.
NOTE: If the available hanging points do not allow for the recommended spacing (or if an alternative hanging method is utilized) then additional hangers may be necessary.
• The spacing between the burner control box mounting brackets and the first hanger should be approximately 2’-4”.
• The space between the first two hangers placed on the first tube should be approximately 8’-10”.
• The space between hangers thereafter, one per tube, should be approximately 9’-8”.
WARNING
Failure to maintain the published clearance to
combustibles may result in fire and/or explosion, property damage, serious injury or death. Always maintain clearances and post signs where needed.
WARNING
Improper suspension
of the heater may result in collapse
and being crushed. Always suspend the appliance from a permanent part of the building structure that can support the total weight and force of the heater.
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Hanger Placement and Suspension
Figure 2.4 • Heater Suspension Layout
NOTE: A sticker identifying the
combustion chamber(s) is located on the swaged end of the tube(s).
Hanging
Point
Burner Control Box Hanging Points
8’-10”
2’-4”
16” Burner
Tube
10 ft. Primary Combustion Chamber
Hanging Point
9’-8”
Hanging
Point
9’-8”
Radiant Emitter
Tube(s)
Radiant Emitter Tube
Igniter/Sensor Box
Burner Control Box
Heater Mounting Requirements and Weights
Model
20 ft. 21’-8” 3 2 120 lbs. 5 6 3 2
30 ft. 31’-4” 4 2 160 lbs. 6 N/A 4 N/A
40 ft. 41’-0” 5 2 190 lbs. 7 8 5 3
50 ft. 50’-8” 6 2 235 lbs. 8 N/A 6 N/A
60 ft. 60’-4” 7 2 265 lbs. 9 10 7 4
Dimension
Straight Config.
Hanging Points
Control Box
Hanging Points
Shipping Weight
Chain Set Qty.
Straight Config.
Chain Set Qty.
U-Tube Config.
Optional Brass
Knuckles (P/N:
5VD54)
12
Optional Single
Mount Bracket
(P/N: 5VD85)
U Config. Only.
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Heater Placement and Suspension
Suspension of the heater must conform to applicable codes referenced in the Safety section and these instructions.
3. Prepare the mounting surface. If necessary, weld blocks, drill holes, etc. Figure 2.5.
NOTE: The burner control box
and radiant tubes should be in straight alignment and level.
Figure 2.5 • Mounting the Hangers
3. I-Beam
4. Beam Clamp
6. Threaded Rod
5. Threaded Rod and Turnbuckle
4. Fasten beam clamp, screw hook or other type of suspension anchor to hanging point.
5. Attach and close S-hook and #1 double-loop chain to anchor. Check that it is securely attached.
NOTE: Threaded rod and
turnbuckles may be used.
3. I-Beam
4. Beam Clamp
5. S-hook and #1 double-loop chain
6. Chain
6. Attach hangers to chains. Adjust chain lengths until radiant tubing is level and equal weight distribution is achieved.
NOTE: Chains must be straight up
and down. Do not install chains at an angle as this can result in tube warpage or separation.
3. Concrete Beam
4. Screw Hook
6. Chain
4.
Screw
hook
with
locknut
and
washer
3. Wood Beam
6. Chain
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Optional U-Bend or Elbow Accessory Configuration
Figure 2.6 • U-Tube Hanger Mounting Options
Single Mounting
Bracket
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Brass Knuckle
Exhaust
End
U-Tubes can be mounted from a single suspension point using a Single Mounting Bracket (P/N: 5VD85) with five S-hooks and #1 double-loop chains.
Figure 2.7 • Angled Hanger Mounting Options
U-Tubes can be mounted at a 15°, 30° or 45° angle with two suspension points, using two Brass Knuckle (P/N: 5VD54) fittings, #1 double-loop chains and S-hooks.
45°
30°
15°
For 45° hanging angle use two S-hooks and two #1 double-loop chains.
For variety of hanging angles, use the Brass Knuckle (P/N: 5VD54) fitting with a #1 double-loop chain and S-hook.
14
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Radiant Tube Assembly
To install the radiant tubes:
1. Place tubes in hangers with the welded seam facing downward and the swaged end of the tube towards the exhaust end of the heater system.
Figure 2.8.
Refer to Figure 2.20 on page 22 for tube installation sequence.
Figure 2.8 • Attach Hangers
Radiant tube
Hanger
2. Slide tube clamps onto radiant tubes. Figure 2.9.
Figure 2.9 • Attach Tube Clamps
Swaged end
Welded seam
faces down
Concave surface
Tube clamp
NOTE: If the tube clamp comes apart, the spacer must be reassembled with the spacer’s concave surface facing against the radiant tube surface.
15
Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Radiant Tube Assembly
3. Slip-fit the radiant tube sections together until tightly connected (install swaged end of each tube towards exhaust end). NOTE: If it is difficult to mate the tubes, they may be installed incorrectly.
4. Center tube clamps over the seams where two radiant tube sections connect. If necessary, rotate tube clamps so they will not interfere with the reflector end caps during expansion and contraction of the heater while operating.
5. Tighten tube clamp bolts to secure. When proper compression is obtained (40-60 ft-lbs. torque), the tube seam will create a visible mark on the tube clamp.
NOTE: Excessive torque may
damage the tube clamp.
The tube clamp is tight when proper torque is achieved (normally when seam becomes visible).
Tubes are not fit snuggly together and the tube clamp is not centered over the seam.
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
• A maximum of one 180° U-bend or two 90° elbows can be installed on a heater.
• Omit one 36” section of turbulator baffle. Refer to Baffle Assembly section.
Optional U-Bend or Elbow Accessory Configurations
Figure 2.11 • Optional Tube Connections
90 Degree
Elbow Bend
(P/N: 3TZ71)
6. Determine the location of the burner control box and note the placement of the mounting chains.
Figure 2.10 • Tube Connections
Tubes fit snuggly together and the tube clamp is centered over the seam.
Correct Tube Connection
Incorrect Tube Connection
A 180 degree U-bend or 90 degree accessory fitting may be installed in the radiant tube heater system. Refer to chart on page 17 for minimum distance requirements from the burner control box.
When installing a U-bend or Elbow Accessory Fitting:
•
The top clearance of an uncovered (no reflector) U-bend or elbow accessory fitting to combustibles is 18”.
• If operating the heater un-vented, separate the intake air to the heater from its exhaust products a minimum of 4’; further separation may be necessary. Combustion air may also be supplied.
180 Degree
U-Bend
(P/N: 3F835)
16
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Radiant Tube Assembly
Figure 2.12 • Elbow and U-Bend Clearances
Dimension A
Elbow can be set
in both directions
Tube Clamp
Tube Clamp
8”
Figure 2.13 • U-Bend and Elbow Dimensions
16”
6”
16”
Dimension A
12”
Dimension B
20”
Tube Clamp
U-Bend can be set in both directions
Tube Clamp
12.5”
12.5”
10”
20”
P/N: 3F835
Minimum Distance from Burner Control Box to U-Bend or Elbow Accessory
Models Dimension A
50-100 MBH 10 ft.
125 MBH 15 ft.
150-175 MBH 20 ft.
200 MBH 25 ft.
P/N: 3TZ71
Overall Dimensions for Heaters Configured with U-Bend (P/N: 3F835)
Model Dimesion B
20 ft. 13’-0”
30 ft. N/A
40 ft. 22’-8”
50 ft. N/A
60 ft. 32’-4”
17
Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Burner Control Box Suspension
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Suspending the burner control box must be done in accordance with applicable codes listed in the Safety section and these instructions.
The burner control box must be in straight alignment with the radiant tubes and level.
1. Determine the mounting chain locations for hanging the burner control box.
2. Fasten beam clamp, screw hook or other type of suspension anchor to hanging point.
3. Attach and close S-hook and #1 double-loop chain to anchor. Check that is securely connected.
4. Attach chain assemblies and
S-hooks to mounting brackets on
the burner control box. Adjust chain lengths until level and in straight alignment with the radiant tubes. The burner sight glass will be visible from the floor.
Figure 2.14 • Burner Control Box Assembly • Side View
1 2
3
Burner Control Box tube is in straight alignment with 10’
4
Primary Combustion Chamber
8.1”
Burner Sight Glass
12”
Figure 2.15 • Burner Control Box with U-Bend • End View
(bottom side of the tube)
16”
29.6”
16”
3.5”
18
5.5”
8.1”
3”
5”
18”
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Reflector Assembly
To install the reflectors:
1. Attach reflector center supports onto radiant tubes.
2. Slide each reflector section through the hangers and adjust the reflector tension spring into the V-groove on the top of the reflector. The reflectors should overlap approximately 4”.
3. To prevent the reflectors from shifting, secure the reflector sections together using sheet metal screws except at the expansion joint. Figure 2.18. NOTE: Installer to provide sheet metal screws.
4. Attach reflector end caps, with polished side inward, to each end of the reflector run.
Reflectors, and reflector accessories, direct infrared energy to the floor level. The reflector assembly depends on the heater configuration, proximity to combustibles and the space surrounding the heater.
Before you begin assembly, determine if the use of reflector accessories are necessary. Figure 2.17.
Figure 2.16 • Reflector Assembly
Hanger
and Chain
Radiant
Tube
Reflector
Reflector Center
Support
Place at the
mid-point
of the tube
Reflector Tension Spring
19
4” Overlap
Reflector
End Cap
Clips
Dayton Installation, Operation, Maintenance and Parts Manual
®
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Dayton Tube Heaters
Reflector Assembly
Common Optional Accessories
Reflector Accessories Description Part #
Elbow Reflector* 90° bend, highly polished aluminum reflector elbow. Designed to fit atop one
elbow accessory fitting.
U-Reflector* 180° bend, highly polished aluminum reflector U-bend. Designed to fit atop
one U-bend accessory fitting.
Side Shield Reflector *^
Protective Guard Used to prevent debris or objects from becoming lodged between the radiant
* Reflectors cannot be rotated when used with this accessory. ^ Refer to the Clearance to Combustibles chart on page 7 for minimum distances to combustibles when side shield
extension(s) are used.
Highly polished side shield extension used to direct infrared rays downward, away from side walls and combustibles.
tube and reflector. Required when mounting heaters below 8 ft.
5VD83
5VD84
5VD86
5VD81
Additional accessory options are available in the W.W. Grainger catalog.
Figure 2.17 • Reflector Shield Accessories
Elbow reflector (P/N: 5VD83) Used over a 90-degree elbow radiant tube.
U-shaped reflector (P/N: 5VD84) Used over a ‘U-shaped radiant tube.
20
Side shield extension (P/N: 5VD86) Directs infrared rays downward, away from sidewalls and combustibles.
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Baffle Assembly and Placement
To assemble the baffles: NOTE: Baffles may be inserted into the
tube while being assembled.
1. Determine the number of baffles needed for your model number. Remove one 36” baffle section if heater is installed with an elbow or U-bend accessory.
Figure 2.18 • Assembling the Baffles
Baffle keyhole
Baffle tabs
2. Install the baffle tabs at a 90° angle to the baffle keyhole.
Figure 2.18.
3. Insert one baffle tab into keyhole and slide completely to one side until both baffle tabs appear in the keyhole.
2
3
4. Adjust the tabs to the center of the keyhole and rotate the baffle 90° to lock the baffle sections together.
5. Repeat this process with remaining baffle sections to complete assembly.
4
To insert the baffles:
1. Insert baffles with the keyhole end first.
2. Rotate baffle assembly so that it is in the vertical position.
Figure 2.19 • Inserting the Baffles
Completed connection
3. Slide baffle assembly into the last radiant tube section, furthest from burner control box.
21
3
NOTE: Baffle assemblies longer than
10’ will continue to be fed into next tube section.
IMPORTANT: Baffle assembly must be flush with the end of the last tube section and in the vertical position.
21
Dayton Installation, Operation, Maintenance and Parts Manual
®
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Dayton Tube Heaters
Final Heater Assembly
NOTICE
Different inputs and models utilize different baffle lengths. Remove all enclosed baffle sections from box and retain with applicable heater. Reference shipping label for proper baffle size.
Each 36” baffle section must be assembled with other baffles and placed in the radiant tube section furthest from the burner. Important: Omit one section of baffle if heater is configured with a U-bend or Elbow accessory fitting.
Figure 2.20 • Secured Reflector Joints and Baffle Location
20 Foot
30 Foot
40 Foot
Key
Burner Control Box with 16” Burner Tube
Expansion Joint on Reflectors
Secured Joint on Reflectors
Primary Combustion Chamber Tube with Clamp
Radiant Tube with Clamp
Baffle Location
50 Foot
60 Foot
22
Dayton Installation, Operation, Maintenance and Parts Manual
!
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Venting
!
WARNING
Insufficient ventilation and/or improperly sealed vents may release
gas into the building
which could result in health problems, carbon monoxide poisoning or death.
Improper venting may result in fire, explosion, injury or death.
Seal vent pipes with high temperature sealant and three (3) #8 sheet metal screws. Vent enclosed spaces and buildings according to the guidelines in this manual and applicable national, state, provincial and local codes.
The heating system may operate either vented or un-vented (see page 27). Venting can terminate through the sidewall (horizontal) or the roof (vertical) and be individually or commonly vented.
Follow these guidelines and all applicable codes for all models, prior to installing vent material. Local codes may vary. In the absence of local codes, refer to the National Fuel Code ANSI Z223.1 (NFPA 54) latest edition or the National Standards of Canada.
Venting Requirements
• 4” single wall galvanized steel vent pipe or Dura/Connect single wall flexible exhaust vent must be used.
• Seal single wall vent with high temperature sealant and three (3) #8 sheet metal screws.
• Single wall galvanized vent pipe must be insulated in cold environments.
• Do not use more than two 90° elbows in the exhaust vent.
• To maintain clearances to combustibles, the use of an approved wall or roof thimble and double-wall Type B-vent is required for the portion of vent pipe that runs through combustible material in the building wall or roof (see figures 2.21 & 2.22).
• The maximum vent length is 20’.
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Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Vent Assembly
Figure 2.21 • General Vent Requirements:
Vent Cap
24 in. Min.*
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Storm Collar
Adjustable Roof Flashing
1 in. minimum clearance
1 in. minimum clearance
B to C Adapter
Single-wall Elbow or Alternate Tee Fitting
*Consult the NFPA ANSI Z223.1 Gas Vent Termination criteria if roof pitch exceeds 9:12
Figure 2.22 • Sidewall Venting Requirements
Roof*
Double-wall B Vent
Firestop Spacer
Heater
Single-wall Vent (field supplied)
Sidewall Venting
Guidelines:
Building
Overhang
Sidewall
Vent Cap
Wall
Thimble
36 in.
min.
6 in. min.
Sidewall
B to C Adapter
Double-wall B-Vent
1/4 in. downward
pitch per foot
Single Wall Vent
24
Heater
• To prevent moisture from entering the heater system, slope the vent pipe down toward the outlet 1/4” per foot of length. Do not pitch the heater.
• Vent must extend beyond any combustible overhang.
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Vent Assembly
Vent Termination
• Vent must terminate a minimum of 4’ (1.2m) below, 4’ (1.2m) horizontally from or 12” (30 cm) above any window or door that may be opened and gravity air inlet into the building.
•
Vent must terminate a minimum of 3’ (.9m) above any forced air inlet that is located within 10’ (3.1m).
• The bottom of the vent terminal must be located a minimum of 12” (30 cm.) above grade level and must extend beyond any combustible overhang. Vents adjacent to public walkways must terminate a minimum a 7’ (2.1 m) above grade level.
• The vent cap must be a minimum of 6’ (15.2 cm) from the sidewall of the building.
Roof Venting
Guidelines:
• Separate air intake duct from vent pipe a minimum of 4’ (1.2 m) by placing vent pipes higher than adjacent air intake duct.
Figure 2.23 • Rooftop Venting - Side View
• Venting may utilize a standard B-vent cap.
• The vent terminal must be installed to prevent blockage by snow and protect building materials from degradation by flue gases.
• Vents must extend beyond any combustible or be a minimum of 36” below a combustible overhang.
• The vent terminal must extend a
minimum of 2’ (.6 m) above the roof.
Vent Cap
Roof
B to C Adapter
Single-wall Elbow or Alternate Tee Fitting
24 in. Min.*
Roof
Double-wall B Vent Pipe
Firestop Spacer
Heater
*Consult the NFPA ANSI Z223.1 Gas Vent Termination criteria if roof pitch exceeds 9:12.
25
Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Vent Requirements
Common Venting
• A dual exhaust assembly (P/N: 3F817) must be used when joining two heaters to a common vent so that by­products of one heater do not flow into the adjoining vent of the other heater.
• 6” diameter double-wall B-vent and 6” vent cap must be used.
• Common vented heaters must be controlled with the same thermostat.
Do not operate individually.
Figure 2.24 • Common Rooftop Venting - Side View
24 in.
Rooftop Vent Cap
Double-wall B Vent
Firestop Spacer
Heater
Min.*
Roof
Heater
Figure 2.25 • Common Sidewall Venting - Top View
Sidewall
6 in. min.
Sidewall Vent Cap
Wall Thimble
Double-wall B-Vent
Single Wall Vent
B To C
Adapter
Dual Exhaust Assembly
Heater
Dual Exhaust Assembly
Heater
*Consult the NFPA ANSI Z223.1 Gas Vent Termination criteria if roof pitch exceeds 9:12.
26
310mm
!
!
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Optional Unvented Operation
When installing in an un-vented configuration:
• A factory supplied vent cap/diffuser (P/N: 3F839) must be used.
• Ventilation of the space is required to dilute the by-products of combustion. Sufficient displacement of fresh air intake and exhaust by­product must be provided.
• The minimum clearance between the air intake and the exhaust terminal is 4’. NOTE: When installing in a U-bend configuration, use caution to separate vent gases from heater intake.
• A minimum positive air displacement (movement) of 4 ft3/1000 Btu/hr input of installed heaters is required.
NOTE: Gravity or mechanical means may be used to accomplish the air displacement. Local codes may require that the mechanical exhaust system be interlocked with the electrical supply line to the heaters, enabling both to function simultaneously.
• The use of combustion air intake is recommended.
Figure 2.26 • Minimum end clearance for unvented heater
WARNING
Not for residential use.
The use of unvented
tube heaters in residential indoor spaces may result in property damage, serious injury or death. Use unvented operation in commercial and industrial installations with proper ventilation rates only.
310mm
12”
12”
27
Dayton Installation, Operation, Maintenance and Parts Manual
®
Dayton Tube Heaters
Combustion Air Requirements
Figure 2.27 • Vertical Outside Air Supply for Single Heater
NOTICE
This heater has a factory preset air orifice for proper combustion air supply. If using combustion air intake from indoors, the required volume of the space must be a minimum of 50 ft3/1000 Btu/hr of installed heater input unless the building is of unusually tight construction. If the building has air infiltration rates of less than 0.40 air changes per hour, outside combustion air is typically needed unless the sheer size of the building allows otherwise.
Non-contaminated air for combustion must be ducted to the heater if chlorinated or fluorinated contaminants, high humidity and other contaminants such as sawdust or welding smoke are present in the area where the heater is installed, or if the building has a negative pressure.
Side View
4” pipe
Figure 2.28 • Horizontal Outside Air Supply for Single Heater Side View
Air Intake
Cap
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Roof Intake Cap
18” Min.
Flexible Air Inlet Boot
Flexible Air Inlet Boot
4” pipe
Wall
Roof
Burner Control Box
Burner Control Box
Combustion air intake may be located on either the sidewall or the roof. Figures 2.27 - 2.29.
Figure 2.29 Vertical Outside Air Supply for Common Heater • Side View
Note: Common
intake heaters must share the same thermostat.
18” Min.
Flexible Air
Inlet Boot
4” pipe4” pipe
Roof Intake Cap
6” pipe
Roof
28
Burner Control Box
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Combustion Air Requirements
Guidelines:
General Requirements
• No more than two 90° elbows are allowed.
• Allow for expansion. Use a 4” flexible hose to connect the duct to the burner control box.
• Do not draw air from attic space.
• In humid environments, use insulated duct, PVC pipe or DWV (drain waste vent) to prevent condensation on the outer surface.
• Separate air intake duct from vent pipe a minimum of 4’. Also, place pipe higher than adjacent air intake duct.
• A factory approved wall intake cap (P/N: 3F837) must be used with horizontal outside intake ducts. The wall intake cap (P/N: 3F837) must be installed to prevent blockage. Locate the intake where dirt, steam, snow, etc. will not contaminate or clog the intake screen.
Limitations for length and size of combustion air intake duct
Single Heater Intake Dual Heater Intake Air Intake Duct Size Max. Intake Length Duct Size Max. Intake Length
4 in. 20 ft. 4 in.(single)/6 in.(dual) 20 ft.
5 in. 30 ft. 4 in.(single)/8 in.(dual) 30 ft
6 in. 40 ft.
Consult factory for longer intake lengths.
Figure 2.30 • Combustion Air Intake
Air Intake Cap
Burner Control Box
29
Dayton Installation, Operation, Maintenance and Parts Manual
!
®
Dayton Tube Heaters
Gas Supply
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
!
WARNING
Improperly connected gas lines may result in fire, explosion, poisonous fumes, toxic gases, asphyxiation or death. Connect gas lines in accordance to national, state, provincial and local codes.
IMPORTANT! Before connecting the gas supply to the burner control box:
• Verify that the heater’s gas type (as listed on the rating plate) match that of your application.
• Check that the gas piping and service has the capacity to handle the total gas consumption of all heaters being installed, as well as any other gas appliances being connected to the supply line.
• Check that the main gas supply line is of proper diameter to supply the required fuel pressures.
• If utilizing used pipe, verify that its condition is clean and comparable to a new pipe. Test all gas supply lines in accordance with local codes.
• Test and confirm that inlet pressures are correct. Refer to the rating plate on the burner control box for required minimum and maximum pressures (see chart below). The gas supply pipe must be of sufficient size to provide the required capacity and inlet pressure to the heater (if necessary, consult the local gas company). Do not exceed the maximum allowed pressure for the heater, the space or the gas piping system.
Manifold Pressure
Required
Type of Gas
Natural 3.5 Inches W.C. 5.0 Inches W.C. 14.0 Inches W.C.
Liquefied Petroleum 10.0 Inches W.C. 11.0 Inches W.C. 14.0 Inches W.C.
Manifold Pressure
Minimum
Inlet Pressure
Maximum
Inlet Pressure
Note: Check manifold pressure at the tap on the gas valve. Readings will be above atmospheric pressure.
Pressure Equivalents: 1 Inch W.C. = .058 oz/sq. in. = 2.49 Mbar
30
Dayton Installation, Operation, Maintenance and Parts Manual
!
!
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Gas Connection
To connect the gas:
WARNING
Failure to install, operate or service this appliance in the approved manner
may result in property damage, injury or death. Only trained, qualified gas installation and service personnel may install or service this equipment.
This heater must be installed and service by trained gas installation and service personnel only.
The installation must conform with local building codes or, in the absence of such codes, the National Fuel Code (NFPA 54) and in conjunction with ANSI Z21.24/CSA 6.10 “Connectors for Gas Appliances”.
IMPORTANT! The heating system will expand and contract during operation. Allowances for expansion must be made between the connection to the heater and the gas supply. Excessive bending, kinks, twists or vibration must be avoided. A flexible gas connection of approved type is required. Flexible stainless steel gas connectors installed in one plane, and without sharp bends, kinks or twists is recommended.
The gas pipe and connection must be supported independently. Do not install gas supply line in a manner that bears the weight of the heater. Connect the main gas supply line with an approved flexible connector (Figures
2.31 & 2.32) or, if national or local codes require rigid piping, a swing joint. See the safety messages at the beginning of this section.
The gas outlet must be in the same room as the appliance and accessible. It may not be concealed within or run through any wall, floor or partition. When installing the heater in a corrosive environment (or near corrosive substances), use a gas connector suitable for the environment. Do not use the gas piping system to electrically ground the heater.
1. Install a sediment trap / drip leg if condensation may occur at any point of the gas supply line. This will decrease the possibly of loose scale or dirt in the supply line entering the heater’s control system and causing a malfunction.
NOTE: High pressure gas above 14 Inches W.C. (water column pressure) requires a high pressure regulator and ball valve.
2. Form the stainless steel flexible connector into a smooth C-shape allowing 12 in. between the flexible connector’s end nuts. Figure 2.31.
3. Attach the ball valve to the gas supply pipe. Apply pipe compound to NPT adapter threads to seal the joint. Use only a pipe compound resistant to LP.
NOTE: Provide a 1/8 in. NPT plugged tapping accessible for test gauge connection immediately upstream of gas connection to the heater (provided on ball valve).
31
Dayton Installation, Operation, Maintenance and Parts Manual
!
®
Dayton Tube Heaters
Gas Supply
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
4. Attach the flexible connector to the adapter and burner control box inlet. Seal the joints.
NOTE: Excessive torque on the manifold may misalign the orifice. Always use two wrenches to tighten mating pipe connections.
5. Final assembly must be tested for
gas leaks according to NFPA or local codes.
!
CAUTION
When using a stainless steel flexible connector, do not attach the connector nuts directly to the gas pipe supply. Connector nuts must be installed to an approved adapter.
Figure 2.31 • Flexible Gas Connection Side View
Ball Valve / Inlet Tap
Adapter
Drip Leg/ Sediment Trap
12”
Stainless Steel Gas Connector, formed into smooth C-Shape
2” max displacement
Heater Movement
Adapter
Burner Control Box
Figure 2.32 • Flexible Gas Connection End View
!
WARNING
Testing for gas leaks with an open flame or other sources of
ignition may lead to a fire or explosion and cause serious injury or death. Test in accordance with NFPA or local codes.
Ball Valve/Inlet Tap
Stainless Steel
Gas Connector
45°
45°
Horizontal
Burner Control Box
Remove cap to clean
sediment trap
32
120V-60 Hz. Supply
NOTE: Up to 4 line voltage tube heaters can be wired to most thermostats.
T
L1
Neutral
Ground
Heaters on the same vent must share the same thermostat.
Additional heaters
Multiple Burner Box
(if applicable)Burner Box
COM
24V
Burner Control Box
w/ 24VAO
L1
N
120 Volt Power
(Observe polarity)
24V Digital
Thermostat
120 V
24V
+
Common
W
R
-
COM
24V
COM
24V
Burner Control Box
w/ 24VAO
Burner Control Box
w/ 24VAO
Common required
for thermostats
that require
constant power.
Common required
for thermostats
that require
constant power.
1/4” spade terminals
required (field supplied)
External
Transformer
(field suppied)
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Electrical Requirements
• Verify that the heater’s voltage (as listed on the rating plate) matches that of your application.
• The heater must be grounded in accordance with the National Electrical Code ANSI/NFPA70 (latest edition).
• Heaters operate on 120 volts, 60Hz., single phase. The maximum amperage requirement is 4.8 amps starting current; 1.1 amps running current per heater.
• It is recommended that the thermostat be installed on the hot side of a fused supply line and have sufficient amp rating for the heater(s) that it controls.
• Observe proper electrical polarity.
Figure 2.33 - Field Wiring 120V Connection(s)
• Clearance to combustibles must be maintained between electrical apparatus and wiring. See clearance data on page 7.
• Wiring must not be run above or below the heater or exposed to the radiant output.
• Installations utilizing a 24 volt thermostat require a relay transformer. Figure 2.34.
Figure 2.34 - Field Wiring 24V Thermostat Connection
33
Dayton Installation, Operation, Maintenance and Parts Manual
Terminal
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
®
Dayton Tube Heaters
Internal Wiring Diagrams
If any of the original wire as supplied with this appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C.
Figure 2.35 • Ladder Diagram: Mark 17DU-117 with Lights
120VACL1
BK
BK
BK
Indicator Lights
BK
BK
Gas Valve
BK
BK
Blower
N
BK
W
G
GND
NEUT
VALVE
BK
Ignitor
Pressure Switch
Flame Rod
O
R
BK
W
BR
TH
SIC1
LINE1
PROBE
NEUT
Ignition Module
Figure 2.36 • Block Diagram: Mark 17DU-117 with Lights
L1
120VAC
N
BK
Block
BK
BK
BK
BK
Pressure Switch
BK
Indicator Lights
BK
BK
BK
O
W
W
R
W
G
Burner
Probe SIC1 Line1 TH Neutral
Valve Neutral
Ground
W
Ignitor
Flame Rod
BK
BR
Ignition Module
W
Blower
Gas Valve
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Dayton Installation, Operation, Maintenance and Parts Manual
!
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Operation
Sequence of Operation
!
WARNING
This heater is not equipped with a pilot ignition system.
Do not attempt to light the system manually.
LIGHTING PROCEDURES:
1. Verify that service lid is secured.
2. Open (turn on) gas supply to the heater.
3. Close (turn on) electrical circuit (typically thermostat).
Starting Circuit
Upon a call for heat, the fan is energized. Once operational static pressure is achieved, the differential switch will close initiating the ignition sequence. After a 5-second delay, the hot surface igniter is energized for 45 seconds and the control allows the gas valve to open.
The trial for ignition is 8 seconds. If flame sense is not established within
8.5 seconds, the heater will attempt two (2) additional ignition sequences before proceeding to soft lockout. Soft lockout automatically retries after one (1) hour or the control can be reset by briefly interrupting the power source.
Running Circuit
After ignition, the flame rod monitors the burner flame. If sense of flame is lost, the control immediately acts to reignite the gas-air mixture (identical to the starting sequence). If flame sense is not established within 8.5 seconds, the heater will attempt two (2) additional ignition sequences before proceeding to soft lockout. The control can be reset by briefly interrupting the power source.
4. If the heater fails to light, turn off gas, open electrical circuit (set thermostat to lowest setting or to off). Wait five (5) minutes before repeating above steps.
SHUTDOWN PROCEDURES:
1. Open (turn off) electrical circuit.
2. Close (turn off) gas supply to the heater.
3. Wait five (5) minutes before relighting heater.
35
Dayton Installation, Operation, Maintenance and Parts Manual
!
!
!
!
!
!
®
Dayton Tube Heaters
Routine Inspection
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
WARNING
Personal injury or death may result if maintenance is not performed by properly trained gas installer or service personnel. Contact the installing distributor or place of purchase for service. Do not
operate heating system if repairs are necessary.
!
WARNING
Allow heater to cool prior to servicing.
WARNING
Disconnect power to heater before servicing.
!
WARNING
Use protective glasses when cleaning the heater.
At least once per year, the heating system should be inspected and serviced by trained gas installation and service personnel only. This inspection should be performed at the beginning of the heating season to insure that all heater components are in proper working order and that the heating system operates at peak performance. Particular attention should be paid to the following items.
• Blower Motor: Annual oiling of the blower motor with SAE 20 oil will extend bearing life significantly. Ensure that the squirrel cage in the blower is kept clean. If dirt becomes a problem, installation of outside air intake ducts for combustion is recommended.
• Vent pipe system: Check the outside termination and the connections at the heater. Inspect the vent exhausts for leakage, damage, fatigue, corrosion and obstructions. If dirt becomes a problem, installation of outside air intake ducts for combustion is recommended.
• Combustion air intake system (when applicable): Check for blockage and/or leakage. Check the outside termination and the connection at the heater.
• Heat exchangers: Check the integrity of the heat exchangers. Replace if there are signs of structural failure. Check for corrosion and/or buildup within the tube exchanger passageways.
• Burner: Check for proper ignition, burner flame and flame sense. Flame should extend directly outward from burner without floating or lifting.
• Wiring: Check electrical connections for tightness and/or corrosion. Check wires for damage.
• Gas Connection: Inspect the integrity of the gas connection to the heater. Check for leaks, damage, fatigue or corrosion. Do not operate if repairs are necessary and turn off gas supply to the heater. Contact service personnel.
• Reflectors: To maintain effective infra-red heating, always keep both sides of the reflector clean. Maintenance can vary significantly depending on the environment. Dirt and dust can be vacuumed or wiped with a soap and water solution. Use metal polish if the reflectors are severely dirty.
Contact service personnel if repairs are necessary. Do not operate unit.
36
Dayton Installation, Operation, Maintenance and Parts Manual
Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Troubleshooting Guide
Symptom Possible Cause Corrective Action
Thermostat closed, fan doesn’t operate. • Blown fuse.
• Faulty thermostat.
• Loose or disconnected wire.
• Faulty fan.
Thermostat closed. Fan operates. Switch does not close.
Note: If hot surface igniter is energized, the indicator light is faulty.
Thermostat closed. Fan operates. Pressure switch closes. No hot su
Thermostat closed. Fan operates. Pressure switch closes. Hot surface igniter energizes. Valve does not open.
Thermostat closed. Fan and hot surface igniter operate. Ignition occurs, burner cycles off in less than 60 seconds.
Thermostat closed. Fan and hot surface igniter operate. After 45 seconds hot surface igniter shuts off. No ignition.
Loss of heater efficiency. • Low gas pressure.
Radiant tube leaking burnt gases. • Loose tube connections.
Condensation. • Stack length is too long.
Tube bowing. • Insufficient combustion air.
Tube corroding. • Contaminated combustion air. • Provide fresh air inlet duct. Visual inspection of burner operation not possible. Stack sooting. • Insufficient combustion air.
Odor or fumes in space (normal during first firing and will subside after initial burn off, approximately 20 minutes).
rface
igniter.
• Loose or disconnected wire.
• Box lid or gasket not in place.
• Plugged pressure switch lines.
• Plugged or restricted exhaust vent.
• Baffle location incorrect.
• Faulty pressure switches.
• Faulty hot surface igniter.
• Faulty circuit board.
• Disconnect gas valve wires.
• Faulty circuit board.
• Faulty gas valve.
• Low gas pressure.
• Baffle improperly positioned.
• Faulty exhaust pressure switch.
• Restricted flue vent.
• No electrical ground.
• Reversed polarity.
• Closed gas supply.
• Dirty or restricted orifice.
• Faulty valve. Disconnected wire.
• Inlet pressure exceeds 14 Inches W.C.
• Dirty or restricted orifice.
• Foreign matter inside burner.
• Unit cycles on and off.
• Reflector is dirty or not in place.
• Clogged fan blower.
• Holes or cracks in radiant tubes.
• Light gauge flue stack used.
• Contaminated combustion air.
• Over fired.
• Contaminated combustion air.
• Heater unable to expand properly.
• Dirty or sooted sight glass.
• Unit mounted upside-down.
• Improper gas.
• Dirty fan or blockage.
• Vaporized solvents decomposing when contacting radiant tubes.
• Evaporation of oils, solvents at floor level.
• Fork lifts.
• Loose tube / vent connections.
• Replace.
• Replace.
• Repair as required.
• Lubricate, repair or replace.
• Repair as required.
• Put in place.
• Clean as necessary.
• Remove foreign matter.
• Re-position baffles at vent end.
• Replace only. Do not adjust.
• Replace.
• Replace.
• Repair as required.
• Replace.
• Replace.
• Provide required gas pressure.
• Re-position baffle at vent end.
• Replace.
• Remove foreign matter.
• Connect electrical ground to junction box.
• Repair.
• Open all gas connections.
• Remove. Clean with a soft object.
• Replace or repair.
• Lower inlet pressure.
• Provide required gas pressure.
• Remove. Clean with a soft object.
• Clean as necessary.
• Check previous symptom.
•
Clean with aluminum cleaner and soft cloth.
• Clean.
• Ensure that tubes are fully connected and clamped properly.
• Replace.
• Shorten stack length.
• Minimum of 26 ga. vent pipe required.
• Provide fresh air inlet duct.
•
Provide 1 sq. in. of free air for every 5,000 BTU/H of input.
• Check gas pressure and orifice size.
• Provide fresh air inlet duct.
• Remount with flexible inlet or vent pipe.
• Remove, clean or replace.
• Mount correctly.
• Provide 1 sq. in. of free air for every 5,000 BTU/H of input.
• Correct with proper gas input (or clean).
• Provide proper ventilation.
• Provide proper ventilation.
• Tighten tube clamps to 50-100 ft-lb.
• Seal vent pipes.
37
15
21
26
14
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
15, 16
13
50
14
49
48
61
30
38
12
34
8
9
10
5
44
6
4
19
40
3
67
45
2
60
68
36, 37
1
11
46
58
41
51
54, 55
39
52, 53
Dayton Installation, Operation, Maintenance and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day - 365 days a year
Please provide following information:
-Part description and number as shown in parts list
-Serial number (if any)
-Model number
7
17
20
47
64
66
17
43
35
42
25
28
27
22
59
65
18
24
63
23
62
Repair Parts Illustration for Dayton Tube Heater
38
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Description Part No. Quantity
No.
Green Self-tap Screw TP-331 1
Potted Circuit Board TP-351A 1
Circuit Board Wiring Harness TP-352A 1
Hot Surface Igniter Plate TP-383 1
Burner Control Box Outer Shell TP-804 1
64
65
66
67
68
Description Part No. Quantity Ref.
Ref.
No.
1 Control Box Cover TP-1 1 35 Plastic Air Orifice w/ Screen - Consult Factory TP-114 1
2 Flange Gasket TP-5 1 36 Burner (50-100 MBH models) TP-200A 1
3 Conduit Coupling TP-9 1 37 Burner (125-200 MBH models) TP-201B 1
Dayton Installation, Operation, Maintenance and Parts Manual
Repair Parts List for Dayton Tube Heater
4 Conduit 4” x 1/2” TP-10 1 38 16” Burner Tube w/ Flange (fittings included) TP-380 1
27 Stainless Steel Flexible Gas Connector TP-83 1 61 Ignition Plate Gasket TP-321 1
28 1/2” Female/Male Flare Fitting TP-84 1 62 120V Amber Operational Indicator Light TP-328 2
29 1/4” x 1/4” Brass Atmos. Barb Fitting TP-97 1 63 1/4” Neutral Terminal Block TP-329 1
30 Aluminum Reflector End Cap TP-105 2
31 Reflector End Cap Clip (pkg. of 8) TP-106 1
32 60” ALUM Radiant Tube w/ Tube Clamp TP-111 1
33 60” Aluminum Reflector TP-112 1
15 120” ALUM Combustion/Radiant Tube TP-26A 1-5 49 Flame Rod TP-222 1
16 120” AL-TI Combustion Tube TP-26B 1 50 Flame Rod Wire TP-222A 1
17 Control Box Mounting Bracket TP-31B 2 51 Gas Manifold TP-223 1
18 1/2” Shut-off Ball Valve/ Inlet Tap TP-33B 1 52 Gas Valve Assembly - Natural Gas TP-240 1
19 Silcone Carbide Hot Surface Igniter TP-50 1 53 Gas Valve Assembly - Propane Gas TP-241 1
20 Fan Blower TP-55A 1 54 Differential Pressure Switch (50-100 MBH) TP-264B 1
21 36” Interlocking Heat Baffle TP-65I 2-5 55 Differential Pressure Switch (125-150 MBH) TP-264E 1
22 2” x 4” Outlet Box TP-66 1 56 Differential Pressure Switch (175 MBH) TP-264D 1
23 2” x 4” Outlet Box Cover TP-67 1 57 Differential Pressure Switch (200 MBH) TP-264F 1
24 Control Box Gasket (per foot) TP-70 6 58 Divider Panel w/ Pressure Switch Mtg. Tabs TP-301 1
25 Rubber Grommet TP-76 1 59 Left End Panel with Light Holes TP-302 1
14 4” Standard Tube Clamp TP-21B 2-6 48 Hot Surface Igniter Holder Gasket TP-221 1
5 Hot Surface Igniter Box TP-11 1 39 Gas Orifice - Consult Factory TP-204 1
6 Hot Surface Igniter Box Cover TP-12 1 40 Hot Surface Igniter Holder TP-205 1
7 8 x 1/2” Self-drilling Screw TP-13 4 41 Pressure Switch Mounting Bracket TP-207 1
8 Sight Glass Gasket TP-14 1 42 Gas Valve Mounting Bracket TP-208B 1
9 Sight Glass TP-15 1 43 1/2” x 3” Pipe Nipple TP-212 1
10 Sight Glass Washer TP-16 1 44 Hot Surface igniter Wiring Harness TP-214 1
13 120” Aluminum Reflector TP-20C 2-6 47 Vinyl Pressure Sensing Tube (burner) TP-219 1
11 Sight Glass Kit TP-17 1 45 Pressure Switch Barb TP-217 1
12 4” Wire Hanger with Tension Spring TP-19B 3-7 46 Vinyl Pressure Sensing Tube (exhaust) TP-218 1
26 Reflector Center Support TP-82 2-6 60 Right End Panel TP-303 1
34 Reflector Tension Spring TP-113 1
• Conversions from natural gas to LP gas require the use of one TP-241 and one TP-204-Size and TP-114-Size.
• Conversions from LP gas to Natural gas require the use of one TP-240 and one TP-204-Size and TP-114-Size.
• Conversions between different BTU’s sizes are not allowed.
39
Dayton Installation, Operation, Maintenance and Parts Manual
®
7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
Dayton Tube Heaters
Limited Warranty
Dayton One-Year Limited Warranty. Dayton Radiant Tube Heaters, Models 7D837A thru 7D849A, 7D851A, 7AR79 thru 7AR88
covered in this manual, are warranted by Dayton Electric Mfg. Co. (Dayton) to the original user against defects in workmanship or materials under normal use for one year after date of purchase. Any part which is determined to be defective in material or workmanship and returned to an authorized service location, as Dayton designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at Dayton’s option. For limited warranty claim procedures, see PROMPT DISPOSITION below. This limited warranty gives purchasers specific legal rights which vary from jurisdiction to jurisdiction.
Additional Limited Warranty. In addition to the above mentioned one-year warranty, Dayton warrants the original purchaser an additional 4-year extension on the combustion chamber, radiant tubes and stainless steel burner. This 4-year extension excludes electrical/purchased components.
General Conditions. Dayton will not be responsible for labor charges for the analysis of a defective condition of the heater or for the installation of replacement parts. The warranties provided herein will not apply if the input of the heater exceeds the rated input at time of manufacturing or if the heater in the judgement of the Company has been subjected to misuse, excessive dust, improper conversion, negligence, accident, corrosive atmospheres, excessive thermal shock, excessive vibration, physical damage to the heater, alterations by unauthorized service personnel, operation contrary to Dayton’s instructions or if the serial number has been altered, defaced or removed. Dayton shall not be liable for any default or delay in the performance of these warranties caused by contingency beyond its control, including war, government restriction or restraints, strikes, fire, flood, short or reduced supply of raw materials, or parts. The warranties herein shall be null and void if the heater is not installed by a competent heating contractor and/ or if the heater is not installed according to Dayton’s instructions, normal industry practices and/or if the heater is not maintained and repaired according to Dayton’s instructions. Normal product degradation and wear (rust, oxidation, etc.) does not constitute a material defect and applicable warranty claim.
Limitation of Liability. To the extent allowable under applicable law, Dayton’s liability for consequential and incidental damages is expressly disclaimed. Dayton’s liability in all events is limited to and shall not exceed the purchase price paid.
Warranty Disclaimer. Dayton has made a diligent effort to provide product information and illustrate the products in this literature accurately; however, such information and illustrations are for the sole purpose of identification, and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose, or that the products will necessarily conform to the illustrations or descriptions. Except as provided below, no warranty or affirmation of fact, expressed or implied, other than as stated in the “LIMITED WARRANTY” above is made or authorized by Dayton.
Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While Dayton attempts to assure that its products comply with as many codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations, and be sure that the product, installation, and use will comply with them.
Certain aspects of disclaimers are not applicable to consumer products: e.g., (a) some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you: (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to you: and (c) by law, during the period of this limited warranty, any implied warranties of implied merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.
Prompt Disposition. Dayton will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address, date and number of dealer’s invoice, and describe the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you, file claim with carrier.
Manufactured for Dayton Electric Mfg. Co., 5959 W. Howard St., Niles, Illinois 60714 U.S.A.
Manufactured for Dayton Electric Mfg. Co. Niles, Illinois 60714 U.S.A.
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