DIRECT GAS FIRED
AIR HEATER
DF SERIES
INSTALLATION
AND OPERATION MANUAL
CUSTOM GAS
SOLUTIONS,
LEGENDARY
PERFORMANCE
Improper installation, modification, adjustment or maintenance may
WARNING
cause damage, injury or death. Carefully read the installation, start-up
and maintenance instructions before installing or servicing this unit.
GAS ODOR
If a gas odor is detected:
1: Open all windows;
2: Do not touch any switches;
3: Extinguish all open flames;
4: Immediately notify your gas supplier.
WARNING
Using or storing fuel or any other flammable liquid or gas in open
containers near this unit is dangerous.
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TABLE OF CONTENTS
TABLE OF CONTENTS ....................................................................................................... 3
CODES REGULATING DIRECT FIRED DUCT HEATERS ........................................................ 4
DF HEATERS INSTALLATION INSTRUCTIONS ................................................................... 5
1. PROFILE PLATE INSTALLATION .................................................................................. 6
2. GAS CONTROL PANEL INSTALLATION ....................................................................... 7
3. GAS PIPING CONNECTIONS ....................................................................................... 8
4. ELECTRICAL CONTROL SENSORS CONNECTIONS ....................................................... 9
5. AIR PRESSURE SWITCH CONNECTION ..................................................................... 10
6. IGNITION AND FLAME DETECTIONS CONNECTIONS ............................................... 10
7. START-UP INSTRUCTIONS ....................................................................................... 12
8. HEATER SHUTDOWN ............................................................................................... 19
9. OPERATING SEQUENCE FOR SINGLE VOLUME DIRECT FIRED HEATER .................... 20
10. OPERATING SEQUENCE FOR DOUBLE VOLUME DIRECT FIRED HEATER ............... 20
11. TROUBLESHOOTING ............................................................................................. 21
START-UP REPORT ......................................................................................................... 28
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CODES REGULATING DIRECT FIRED DUCT HEATERS
Direct fired duct heaters must be installed according to local installation code for gas
equipment and any provincial or state regulations applying to this category of
equipment.
Furthermore, when suspending this unit, the following ANSI standards must be
followed: ANSI/NFPA 409 for aircraft hangars, ANSI/NFPA 88A or ANSI/NFPA 88B and
CAN/CGA B 149 in effect for public garages. Electrical installations must meet the
standards stated in the first part of the C22.1 Canadian electrical code of with the
National Electric Code ANSI/NFPA 70 in the USA, and all local applicable codes for this
category of equipment.
All electrical installations must comply with the electric diagrams of the heater. For
more information, refer to the start-up instructions, operating and adjustments
instructions and wiring diagram supplied with the unit.
WARNING
This air heater must ALWAYS:
• Be used to heat outside air (100% fresh air). No recirculation air is allowed.
• Be used to replace air exhausted from a building or through process
equipment;
• Supply air at a temperature not exceeding 72°C (160°F) or as stated in the
applicable local code.
THIS HEATER IS NOT A SPACE HEATER AND SHOULD NOT BE
USED AS SUCH. THIS HEATER MUST NOT BE USED ANYWHERE
PEOPLE MAY SLEEP.
IMPORTANT
Allow the recommended clearances upstream and downstream of the burner.
Refer to "Profile Plate Installation" section.
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Profile plate
DF HEATERS INSTALLATION INSTRUCTIONS
There are 7 important steps to follow when installing the duct heater. Please read this
manual carefully and follow the instructions.
1. Profile plate installation.
2. Control panel installation.
3. Gas piping connections (main burner, pilot and vents).
4. Electrical control sensors connections.
5. Differential pressure switches connections.
6. Ignition wire and flame detection rod connections or ultra-violet detector
connections.
7. Start-up instructions.
Control panel
DF HEATERS TYPICAL ASSEMBLY
Burner
Gas inlet
Consult the manufacturer for any other assembly arrangement.
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*: if water coils or flat filters are installed upstream this dimension has to be increased.
1. PROFILE PLATE INSTALLATION
Install the profile plate according to the following clearances.
If heater is shipped assembled make a large enough opening in unit casing to
allow the insertion of the profile plate at the chosen location.
CLEARANCES TO BE RESPECTED
WARNING
Table of clearances
Model F G* H**
in mm in mm in mm
DF-25, -50, -75, -100
DF-150
DF-200, -300, -375 40 1016
DF-450, -550, -700 18 457 50 1270
**: if a plenum fan is used, this dimension has to be increased by 50% or consult the manufacturer.
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1 25
6 152
12 305
30 762
2. GAS CONTROL PANEL INSTALLATION
Locate the control panel so that the main gas pipeline (gas outlet) towards the burner is
upstream of the profiled plate which represents approximately a third of the width of
the control panel length.
TYPICAL PIPING SCHEMATIC OF AN INSTALLATION WITH THE PANEL
MOUNTED DIRECTLY ON UNIT
TYPICAL PIPING SCHEMATIC OF AN INSTALLATION WITH THE
PANEL REMOTELY MOUNTED FROM UNIT
NOTE: It is possible to install the control panel remotely from the profile plate. Standard
wires and tubes length provided with the heater is six feet (two meters). For installation
requiring a longer distance of wires and tubes, please consult the manufacturer.
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1,2
3. GAS PIPING CONNECTIONS
(MAIN BURNER, PILOT AND VENTS)
For units installed indoors, bleed and vent
connections must be extended to the
outdoor in accordance with local codes.
Gas piping connections
With a NPT1 pipe
diameter of this size...
¾" 1 ⅛" (29mm) 6" (152mm)
Main gas piping
1" 1 ⅜" (35mm) 6" (152mm)
1 ½" 2" (51mm) 6" (152mm)
2" 2 ½" (64mm) 6" (152mm)
3" 3 ⅝" (92mm) 6" (152mm)
Pilot piping ½" ⅞" (22mm) 6" (152mm)
Gas connection pipe size (NPT)
Gas inlet
Capacity
3
and outlet
(½ psig) Gas outlet (2 psig)
750 MBH and less ¾"
From 751 to 1000 MBH 1"
From 1001 to 2500 MBH 1 ½" 1 ½" 1 ½"
From 2501 to 5000 MBH 2" 1 ½" 2"
5001 MBH and more 3" 2" 3"
Pilot, vent and bleed valve pipe size (NPT)
Capacity Pilot line diameter Vent diameter Bleed valve
750 MBH and less
From 751 to 1000 MBH
From 1001 to 2500 MBH
From 2501 to 5000 MBH
5001 MBH and more
¼" aluminum tubing
...Drill a hole of this size
in unit wall
Pipe length extended
outside control cabinet
Gas inlet (2 psig)
Use external gas regulator to reduce to ½ psig
1,2
4
(IRI option)
Not required (2 x 2" Ø
openings are required
in cabinet for
ventilation)
¾"
1"
1 ½"
1
NPT: National pipe thread
2
This table is not intended for gas line sizing.
3
If gas pressure exceeds ½ psi (14" w.c.), a high pressure regulator capable of modulating in a ratio of 40:1 must be added
at the unit inlet in order to adequately regulate the pressure at low fire.
4
Bleed valve vent piping to the exterior must not be connected to other vents.
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4. ELECTRICAL CONTROL SENSORS CONNECTIONS
The sensors connections must be carried out by a qualified electrician,
respecting the unit’s electrical diagram and according to local codes.
The sequence of operation of the electrical diagram must never be modified
without consulting the manufacturer.
Electrical controls location (Installed by others)
WARNING
Items Description (All wires must comply with codes, and in their absence, National Electrical Code NFPA70)
1 Low temperature limit sensor (Freeze stat, optional) (BL)
2 Modulation sensor (MT1-12/TS114) (Shielded wires required)
3 High limit air temperature control (max. 160°F)(HL)
4 Air inlet temperature sensor (TDA) (Optional)
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