Reznor VCS100 Installation Manual

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Page 1

INSTALLATION / OPERATION / MAINTENANCE

Applies to: Model VCS/VCT 120V 60Hz

Gas-Fired, Tubular, Radiant,

Low-Intensity Infrared Heater

Model VCS/VCT (Harsh Environment )

On/Off & High/Low Burner/Control Box

with 20 - 80 ft Tube/Reflector Length

Doc No 700102 (06-15), Page

Part No. 270685

Page 2

Introduction.

Welcome to the new range of powered Harsh Environment infrared heaters. Local regulations may vary and it is the installer’s responsibility to ensure that such regulations are satisfied.

All installation, assembly, commissioning and service procedures must be carried out by suitable qualified competent persons and conform with local building codes, or in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1/NFPA 54 or the National Gas and Propane Installation Code CSA B149.1.

When assembling, installing, commissioning

Document Index.

1 Installation Requirements

1.1 Health & Safety

1.2 Heater Suspension

1.3 Clearance to Combustibles

1.4 Gas Connection & Supply Details

1.5 Electrical Connections

1.5.1 Multiple Burner Detials

1.5.2 Multiple Burners via Ind Power Source

1.6 Ventilation Requirements

1.6.1 Unvented Units

1.6.2 Vertical Venting

1.6.3 Horizontal Venting

1.7 Fresh Air Intake

1.8 Technical Details

2 Assembly Instructions

2.1 Tools Required

2.2 Assembly Notes

2.2.1 Emitter Tubes

2.2.2 Turbulators

2.2.3 Brackets

2.2.4 Couplers

2.2.5 Reflectors

2.2.6 End Caps (optional)

2.2.7 Bends (where required)

2.2.8 Burner/Fan Assembly

and servicing is undertaken on radiant tube heaters specified in these instructions, due care and attention is required to ensure that working at height regulations are adhered to

PLEASE READ this document prior to

installation to familiarize yourself with the components and tools you require at the various stages of assembly.

All dimensions shown are in inches unless otherwise stated.

The manufacturer reserves the right to alter specifications without prior notice.

2.2.9 Detailed Assembly Drawings

3 Start Up Instructions

3.1 Tools Required

3.2 Start up procedure

4 Servicing Instructions

4.1 Tools Required

4.2 Burner Description

4.3 Burner Removal

4.4 Burner Gas Injector Servicing

4.5 Burner Head and Electrode Servicing

4.6 Combustion Fan Assembly

4.7 Emitter Tube Servicing

4.8 Reflector Servicing

4.9 Cleaning of Vent

4.10 Re-commissioning after Service

5 Troubleshooting Guide 6 Replacing Parts

6.1 Burner Controller Replacement

6.2 Air Pressure Switch Replacement

6.3 Gas Valve Replacement

7 User and Operating Instructions

7.1 To Start Heater

7.2 To Switch Off Heater

7.3 Servicing

1. Installation Requirements.

1.1 Health and Safety

A. Heater is intended for heating outdoor or

non-residential indoor spaces and should only be installed where flammable gases or vapours are not present.

B. Heaters can be suspended horizontally or at

any angle along the axis of the emitter tubes but can only be rotated about the burner head 0 to 55°. See section 1.3 for clearance dimensions.

Doc No 700102 (06-15), Page 2

C. The installation must conform with local

D. The unit shall be electrically grounded in

E. The heater may be installed in aircraft

building codes or, in the absence of local codes, with the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CSA B149.1.

accordance with National Electric Code ANSI/NFPA 70 and Canadian Electrical Code CSA C22.1.

hangars in accordance with the Standard for

Page 3

Aircraft Hangars, ANSI/NFPA 409 and in automotive garages when installed in accordance with the Standard for Parking Structures, ANSI/NFPA 88A, or the Standard for Repair Garages, ANSI/NFPA

88B, or the Canadian Natural Gas and Propane Installation Code, CSA B149.1,

and are so marked.Ensure that minimum clearances will be maintained to vehicles parked below the heater.

F. The standard heaters are approved for installations between 0 - 2000ft (0 - 610m) above sea level for the US and 0 - 4500 ft (1370m) above sea level for Canada. Conversion kits are available on installations above these heights in the USA.

G. Massachusetts Requirement: If the heater is being installed in the Commonwealth of Massachusetts, this unit must be installed by a licensed plumber or licenced gas fitter.

Note: Any outdoor installations must be installed with a vent cap at the inlet and

the flue end.

1.2 Heater Suspension

Attachment to the heater support lugs should

be made by D shackle. The hanging attachments to overhead steelwork etc. have to be designed and produced in accordance with sound engineering practices. They must be adequately fixed and designed to carry the whole weight of the heater. In the event of suitable roof steelwork being unavailable, additional steelwork should be fitted to enable vertical hangers to be used for suspending the heaters.

These methods are illustrated in Figure 1. If there are any doubts as to the strength or suitability of roof steelwork to which heaters are to be suspended, please refer to a Consultant, Architect or owner of the building.

It is recommended that the heater is raised to its final position once the assembly of the emitter tube/bracket/reflector has been completed. Longer tube assemblies may be raised in more than one sub-assembly with final emitter tube connection made in the air.

Ensure that the installer uses the burner roof support mounting bracket when suspending the heater. This is situated on the front of the burner. When packed the bracket is reversed and must be turned to its correct state for mounting. (ref page 22.)

WARNING:

If not installed, operated and maintained in accordance with the manufacturer’s instructions, this product could expose you to substances in fuel or from fuel combustion which are known to the state of California to cause cancer, birth defects or other reproductive harm.

U TUBE VARIANTS

NOTE. 'S' HOOKS ARE TO

BE CLOSED UP AFTER ASSEMBLY

SUITABLE CHAIN

WORKING LOAD

LIMIT 100LB

EXHAUST

END

CHAIN

55° SUSPENSION

Figure 1. Recommended Methods of Heater Suspension.

Doc No 700102 (06-15), Page 3

BURNER

END

Page 4

ON VENTED HEATERS, THE HEATER SHOULD SLOPE DOWNWARDS AWAY FROM THE BURNER AND ON UNVENTED HEATERS SHOULD SLOPE DOWNWARDS TOWARDS BURNER BY APPROX. ½” FOR HORIZONTAL INSTALLATIONS AS SHOWN BELOW (DIAGRAMS EXAGGERATED FOR CLARITY)

1/2”

VENTED

1/2”

UNVENTED

1.3 Clearance to Combustibles.

Minimum clearance to combustibles are shown in Table 1 below.

IMPORTANT:

The stated clearance to combustibles represents a surface temperature of 90°F (50° C) above room temperature. Building material 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.

Table 1

MODEL A A1 / A2 B B1 C1 C2 C3 D1 D2 E

Clearance to Combustibles, inches (cm)

(188)

(74)

(105)

20 (51) /

10* (26)*

(21)

(56)

(21)

(31)

(188)

(74)

(105)

20 (51) /

10* (26)*

(21)

(56)

(21)

(31)

15° = 72 (183) 25° = 68 (173)

100

(188)

35° = 61 (155) 45° = 53 (135)

(82)

(105)

20 (51) /

10* (26)*

(21)

(56)

(21)

(41)

(31)

55° = 43 (110)

125

150

170

(188)

(219)

15° = 82 (209) 25° = 78 (199)

(99)

(122)

(120)

(122)

20 (51) /

10* (26)*

20 (51) /

10* (26)*

20 (51) /

10* (26)*

(21)

(28)

(56)

(51)

(46)

(51)

(31)

35° = 71 (181) 45° = 61 (155)

200

* distance with end caps fitted.

(219)

WARNING:

55° = 50 (127)

Minimum clearance from the heater must be maintained from vehicles parked below heater. In all situations, clearances to combustibles must be

(122)

20 (51) /

10* (26)*

(28)

(56)

(51)

(31)

maintained. Signs should be posted in storage areas to specify maximum stacking height to maintain required clearance to combustibles. Such signs must either be posted adjacent to the heater thermostats or in the absence of such thermostats in a conspicuous location. Refer to mounting clearance tables.

Doc No 700102 (06-15), Page 4

Page 5

Figure 2 Clearance to Combustibles (Standard indoor reflectors)..

The minimum clearances to combustible materials are given in Table 1 These minimum

distances MUST be adhered to at all times. Adequate clearance MUST be provided around air openings into the combustion chamber and there MUST be suitable clearance for accessibility and for combustion / ventilating air supplies.

0° to 55°

Angled view.

Return end on

U tube heater

WARNING!

combustion and ventilation air supply.

provision in the building for

Ensure that there is adequate

Installation must meet minimum

requirements and applicable codes.

Below

Outlet end.

heater

End

Side

unvented

Above outlet

Above

Reflector

Burner end.

Side

vented

Doc No 700102 (06-15), Page 5

End view.

Above

Burner

Above

Burner

Service

distance

Service

distance

Page 6

1.4 Gas Connection and Supply

WARNING: Before installation, check

that the local distribution conditions, nature of gas and pressure, and adjustment of the appliance are compatible.

The gas connection on the heater is ½” N.P.T internal thread.

Injector sizes and manifold pressure for the burners are shown in the table 4. The gas supply piping and connections must be installed so that the minimum pressure stated is achieved.

A gas shut off valve and union should be fitted in the gas supply line close to the heater and a ⅛” N.P.T plugged tapping, accessible for test gauge connection, provided immediately upstream of the appliance gas inlet.

It is essential to provide some flexibility in the final gas connection by use of an approved flexible gas connector. (See Fig 4.)

Take care when making a gas connection to the heater not to apply excessive

turning force to the internal controls.

Care must be taken to observe the pipe bend diameter of 12” (30cm) and pipe displacement distance of 3” (7.62cm).

The correct installation as shown will allow for approx 4” of movement due to

expansion.

Figure 3. Correct orientation of Ball Valve

Gas Flow

Figure 4. Correct Installation of Flexible Gas Connection

* Connector must be certified for use on a radiant tube type infrared heater and must comply with Standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 or with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas, CAN/CGA 8.1.

For heaters up to 150,000Btu/h, ½” ID x 24” long For heaters 150,000Btu/h and above, ¾” ID x 36” long NOTE: For Canada all heaters MUST use a hose 36” long (See Table 3)

Table 3

HOSE SIZE USA CANADA

3/4” CE4

CONTACT FACTORY

WARNING: FIRE OR EXPLOSION HAZARD - It is essential to provide some flexibility in

the final gas line connection by use of an approved flexible connector as shown in the

drawings. Expansion of the radiant pipe occurs with each firing cycle causing the burner to move with respect to the gas line. This can result in a gas leak producing an unsafe condition.

Doc No 700102 (06-15), Page 6

Page 7

CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. FOR HEATERS UP

TO 150,000 BTU/H, A 24” LONG CONNECTOR OF AT LEAST ½” ID MUST BE USED. FOR HEATERS ABOVE 150,000 BTU/H, A 36” LONG CONNECTOR OF AT LEAST ¾” NOMINAL ID MUST BE USED.

Table 4 Gas Supply Pressures

Gas Type

Natural Gas LP/Propane Gas

Model VCS VCT VCS/VCT

Min Required Gas Pressure (in W.C) (60,000 TO 150,000 BTU)

Min Required Gas Pressure (in W.C) (170,000 TO 200,000 BTU)

Max Supply Pressure (in W.C)

5.0 7.0 11.0

7.0 7.0 11.0

14.0 14.0 14.0

Gas Supply Connection ½” N.P.T thread

1.5 Electrical Connections

Important: All electrical work should be done by a qualified electrician in strict accordance with the

WARNING: Before making electrical

connections, switch OFF the main electrical disconnect. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Electrical shock can cause personal injury or death.

National Electrical Code ANSI/NFPA 70 or Canadian Codes CSA C22.1.

The electrical supply to the heater is by three wires: hot (Live), neutral and ground connections.

Install in accordance with

This appliance must be electrically grounded

Supply 120V 60Hz single phase. Standard heater 0.16HP. Current rating (inductive):

1.8 amp max (models 60 - 150)

1.0 amp max (models 170 & 200)

all state & local codes.

Where alternative manufacturers controls are used, please refer to their instructions for their installation details.

Fuse: external 3 amp.

Figure 5a. External Wiring Schematic (VCS)

24V AC Single Stage

Thermostat (Ext.)

Burner 1

24V AC

Terminals

(120V AC Fan

Terminals)

Doc No 700102 (06-15), Page 7

120V AC

Supply

KEY:

BK-BLACK

BL-BLUE

R-RED

G-GREEN

W-WHITE

Notes:

Use 18/4 class 2 thermostat cable between heater and thermostat.

Max. length @ 18 Awg (0.8mm²) = 100ft.

Only one burner can operate from one thermostat as supplied.

When servicing heaters ensure the electricity supply is isolated from the mains supply.

120V AC supply is still present at each burner when the thermostat is switched off.

Page 8

Figure 5b. Single and Multiple Heater Installations 120V Control (VCS)

120V Thermostat

110V Thermostat

KEY: G-GREEN W-WHITE BK-BLACK

Burner 1

If heaters are wired using the method

shown above, a link wire must be fitted to the burner terminals as shown in the diagram opposite.

GND L2 L1 (HOT)

120V 60Hz 1 Ph Supply circuit

Other burners

other burners

Burner

Link

Figure 5c. External Wiring Schematic. (VCT)

24V AC 2-Stage

Thermostat (Ext.)

Burner 1

24V AC

Terminals

(120V AC Fan

Terminals)

BL R

120V AC

Supply

W1 W2

KEY:

BK-BLACK

BL-BLUE

R-RED

O-ORANGE

G-GREEN

W-WHITE

Notes:

Use 18/4 class 2 thermostat cable between heater and thermostat.

Max. length @ 18 Awg (0.8mm²) = 100ft.

Only one burner can operate from one thermostat as supplied.

When servicing heaters ensure the electricity supply is isolated from the mains supply.

120V AC supply is still present at each burner when the thermostat is switched off.

Doc No 700102 (06-15), Page 8

Page 9

Figure 6a. Internal Burner Wiring Diagram. (VCS)

Optional

24V single

stage

Thermostat

CW1R

24V Stat

Terminals

Pressure Switch

120V AC

Supply

LNE

BL - BLUE

KEY:

120V AC Fan

Terminals

CW1R

BK - BLACK

BR - BROWN

GR - GREY

G - GREEN

W - WHITE

Y - YELLOW

O - ORANGE

P - PURPLE

120v/24VAC 60Hz

Power ON (red)

Transformer

BL BR

PGR

Burner On (amber)

PS1

PS0

Gas Control

COM

Gas Valve

IND

NOTES:-

Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner. Additional wiring is required to install an optional extra thermostat and / or time clock. If no thermostat is required then a jumper is fitted between terminals R and W1. In this configuration the burner will continuously fire until the 120V power supply is disconnected. Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 220°F/105°C

Doc No 700102 (06-15), Page 9

Page 10

Figure 6b. Internal Burner Wiring Diagram. (VCT)

24V Two stage

Thermostat

24V AC Stat

Terminals

Pressure Switch

W2W1

120V AC Fan

120V AC

Terminals

W2W1

F1 NEF2

Supply

LNE

KEY:

BL - BLUE

BK - BLACK

BR - BROWN

GR - GREY G - GREEN

K - PINK

R - RED

W - WHITE

Y - YELLOW

120V/24VAC 60Hz

Transformer

O - ORANGE

P - PURPLE

Power ON (red)

BL BR

High Fire

Low Fire

Relay

1222

24V AC RELAY

COIL

1424

COM

IND

PS1

PS0

COM

Gas Control

(amber)

High Fire

NOTES:Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner.

Additional wiring is required to install an optional extra thermostat and / or time clock. Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C

PGR

KGR

Gas Valve

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 220°F/105°C

Doc No 700102 (06-15), Page 10

Page 11

1.5.1 Multiple burner configurations (Master & Slave) via Optional Relay (VCT ONLY). Refer to figure 6c and 6e.

Multiple VCT burners can be controlled via one main burner. In this scenario the main burner is knows as the ‘Master’ and any additional burners are known as ‘Slaves’.

The external two stage thermostat is connected to the Master burner and powered via the inbuilt transformer. The total burner load for the Master is 20VA. Each additional ‘Slave’ burner is 1.6VA

The Thermostat chosen to control the multiple heaters must not have a power requirement exceeding the spare capacity as shown in the examples below.

CONFIGURATION TOTAL BURNER LOAD SPARE FOR THERMOSTAT

Master PLUS 1 Slave 21.6VA

Master PLUS 3 Slaves 24.8VA

Master PLUS 5 Slaves 28.0VA

Master PLUS 7 Slaves 31.3VA

18.4VA

15.2VA

12.0VA

8.8VA

Figure 6c. Wiring schematic. Multiple Burners Master and Slave. (VCT)

GND L2 L1 (HOT)

120V 60Hz 1 Ph

Supply circuit

THERMOSTAT

W1 W2

R C

R C W1 W2

MASTER

BURNER

LEN

SLAVE

BURNER

W1 W2

LENLENLEN

SLAVE

BURNER

W1 W2 W1 W2

SLAVE

BURNER

24VAC 60Hz 1 Ph Hi/Lo circuit

1.5.2 Multiple burner configuration via independently powered two stage thermostats. (VCT ONLY). Refer figs 6d & 6e

Note: If the thermostat has an independent power supply, all burners in the zone to be controlled MUST be Slave burners.

The maximum number of Slave burners per thermostat is dependent on the maximum power output of the thermostat selected.

Each ‘Slave’ burner is rated at 1.6VA 24VAC 60Hz.

The external two stage thermostat is powered via its own power supply and must output to each Slave burner - 24VAC for low fire to terminal W1 and 24VAC for hi fire to both terminals W1 and W2

Refer to thermostat manufactures literature for details.

Figure 6d. Wiring schematic. Multiple Burners via independently powered Relay. (VCT)

GND L2 L1 (HOT)

120V 60Hz 1 Ph Supply circuit

Low fire output

Hi fire output

THERMOSTAT

W1 W2

SLAVE

BURNER

LEN

SLAVE

BURNER

W1 W2

LENLENLEN

SLAVE

BURNER

W1 W2 W1 W2

SLAVE

BURNER

Supply Circuit

(by others)

Doc No 700102 (06-15), Page 11

24VAC 60Hz 1 Ph Hi/Lo circuit

Page 12

Figure 6e. Internal Slave Burner Wiring/External Schematic Diagram with Optional Relay. (VCT)

1222

24V AC

RELAY

COIL

1424

OPTIONAL RELAY WIRING

COM

Relay mini harness leads

5A connector

24V Two stage

Thermostat

24V AC Stat

Terminals

Pressure Switch

W2W1

120V AC Fan

Terminals

W2W1

F1 NEF2

120V AC

Supply

LNE

KEY:

BL - BLUE

BK - BLACK

BR - BROWN

GR - GREY

G - GREEN

K - PINK

R - RED

W - WHITE

Y - YELLOW

120V/24VAC 60Hz

Transformer

O - ORANGE

P - PURPLE

Power ON (red)

BL BR

PGR

High Fire

Relay

1222

24V AC RELAY

COIL

1424

COM

IND

PS1

PS0

COM

Gas Control

Low Fire

(amber)

High Fire

KGR

Gas Valve

NOTES:Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner. Additional wiring is required to install an optional extra thermostat and / or time clock. Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 220°F/105°C

Doc No 700102 (06-15), Page 12

Page 13

1.6 Vent Requirements and Details

1.6.1 Unvented units

Heaters may be installed unvented providing the governing building codes are met and consideration is properly given to possibilities of condensation on cold surfaces.

Installation shall meet the following requirements when unvented:

• Natural or mechanical means shall be provided to supply and exhaust at least 4 CFM per 1000 BTU per hour input of installed heaters.

• Combustion gases shall not impinge on combustible materials.

1.6.2 Vertical venting

The heater can be installed with a vertical vent.

All vent piping should be adequately supported from the building structure and terminated with an approved terminal.

recommended vent length is 25ft (7.6m) with a maximum of two elbows

should be properly sealed. refer fig 7a

1.6.3 Horizontal venting

Individual units can be vented horizontally through side walls. Recommended terminals are Part Numbers 111848 for 4” and 111850 for 6”.

Distances from adjacent public walkways, adjacent buildings, openable windows and building openings, consistent with the National

Fuel Gas Code, ANSI Z223.1/NFPA 54 or the Natural Gas and Propane Installation Code, CSA B149.1.

The maximum recommended vent length is 25ft (7.6m) with a maximum of two 90° elbows.

However runs up to 12ft (3.6m) can use 4” (101mm) vent pipe. Runs over 12ft (3.6m) should always use 6” (152mm) vent pipe.

An approved clearance thimble is required when the flue pipe passes through combustible materials. Follow the requirements of the thimble manufacturer.

Standard vent terminals must extend at least 6” (152mm) from the wall and at least

The maximum

. All connections

24” (609mm) from any combustible overhang. This protects the building material from degradation by the vent gases.

Vent joints should be sealed and secured according to the vent manufacturers instructions. Should condensation occur the vent should be shortened or insulated.

The terminal should be at least 3ft (0.91m) from any air intake to the building.

The vent terminal must be installed at a suitable height above the ground to prevent blockage by snow.

1.7 Fresh Air Intake

Whenever the heater is installed in locations where airborne dust or other pollutants are present, a fresh air supply should be ducted to the burner.

If the heater is equipped with ducted combustion air, the vent terminal must be at least 3ft (0.91m) away from the air inlet and located higher than the inlet.

A fresh air duct of 4” (101mm) diameter should be installed from the fresh air to the air intake connection on the fan housing. A flexible jointing piece should be installed at the fan connection with hose clamps to facilitate expansion and contraction.

The maximum recommended length air duct is 25ft (7.6m) and the maximum number of elbows is two. The minimum length is 18” (456mm).

The location of the fresh air duct inlet must be where it will receive dust free clean air. An inlet cap with bird screen must be fitted at the inlet of the duct. If the duct inlet is located above the roof the underside of the inlet terminal must be at least 2ft (0.61m) above roof level (or above projected snow load) and at least 10” (254mm) above any projection on the roof within 7ft (2.1m) of the inlet. Intake pipe, fittings and sealant are not furnished by the manufacturer. Refer fig 7c & d.

Note the vent terminal must NOT be installed below the fresh air intake, and should have a minimum separation distance of 36” from the air intake.

Note The vent terminal should be installed so as to be in the same atmospheric pressure zone as the combustion air inlet of the appliance.

Doc No 700102 (06-15), Page 13

Page 14

Figure 7.a Vertical Venting.

Approved clearance thimble is required when the flue pipe extends through combustible materials. Follow the requirements of the thimble and/or Category III vent pipe manufacturer.

Figure 7.b Horizontal Venting (plan view shown).

Approved clearance thimble is required when the flue pipe extends through combustible materials. Follow the requirements of the thimble and/or Category III vent pipe manufacturer.

Aluminum 4” (101mm) O.D. pipe.

Max length = 25’0” (7.62M) with 2

x 90° long radius bends.

Clamps

4” (101mm) O.D. flexible duct

Burner

Note The vent terminal should be installed so as to be in the same atmospheric pressure zone as the combustion air inlet of the appliance.

Note the vent terminal must NOT be installed below the fresh air intake, and should have a minimum separation distance of 36” from the air intake.

Figure 7.c Fresh Air Ducted Intake.

Doc No 700102 (06-15), Page 14

Page 15

1.8.1 Technical Details - Table 5a (VCS)

No of Injectors

Gas Connection

Electrical Supply

Vent size (in)

Unitary Fan Motor Details

Current Rating

Ignition

Natural Gas LP Gas

MODEL

BTU/Hr BTU/Hr

60,000 60,000 20 40 20 40

120 volt 1 phase 60Hz

4” or 6” (101mm or 152mm)

120 volt, 1 phase 60Hz

1.8A MAX (models 60 - 150); 1.0A MAX (models 170 & 200) Electronic Program Start up with Spark Ignition

Min. Heater

Length

Max. Heater

Length

S ft S ft U ft U ft

½” N.P.T

Min. Heater

Length

Max. Heater

Length

80 80,000 80,000 30 40 20 40

100 100,000 100,000 30 50 40 40

125 123,500 125,000 30 60 40 60

150 150,000 150,000 40 70 40 60

170 169,000 169,000 50 80 60 80

200

Appliances can be installed up to 10,000ft above sea level in the USA. Altitude conversion kits are available on request.

200,000

N/A

50 80 60 80

USA 0- 2000 ft (0-610m) above sea level

Size

NG “WC

LP “WC

60 80 100 125 150 170 200

3.9 3.5 4.5 4.3 4.0 3.3 3.3

5.5 5.2 8.0 7.6 7.0 6.1 N/A

USA & CANADA Natural Gas 0- 2000 ft (0-610m) above sea level

Size

Burner Orifice Plate Part No.

60 80 100 125 150 170 200

269941 269942 269943 269944 1005513 269946 269946

Flame Plate Part No.

Fan Part No.

Fan Orifice Part No.

Injector Part No.

270476 270476 270476 270476 270476 269922 269925 269925 269930 269931 269935 269938 270400 270402 270403 270405 270407 270409 270410

Injector Carrier Part No.

Pressure Switch Part No.

USA & CANADA LP Gas 0- 2000 ft (0-610m) above sea level

Size

Burner Orifice Plate Part No.

Flame Plate Part No.

60 80 100 125 150 170 200 269948 269949 269950 269951 269952 269953 269957 269958 269960

Fan Part No.

Fan Orifice Part No.

Injector Part No.

269924 269925 269929 269931 269933 269937 270398 270399 270400 270401 270403

Injector Carrier Part No.

Pressure Switch Part No.

CANADA 0- 2000 ft (0-610m) above sea level

Size

NG “WC

LP “WC

270375 270376

270476 270475

60 80 100 125 150 170 200

3.9 3.5 4.5 4.3 4.0 3.3 3.3

5.5 5.2 8.0 7.6 7.0 6.1 N/A

N/A

270475

270389 270390

269959

N/A

270375 270389

Doc No 700102 (06-15), Page 15

Page 16

Technical Details VCS continued

MODEL

VCS

100

125

150

170

200

MODEL

VCS

100

125

150

170

200

U Tube Straight Tube

U20 U40 U60 U80 S20 S30 S40 S50 S60 S70 S80

● ●

● ● ●

● ● ● ●

● ● ● ● ● ●

Emitter Tube Type Material

Calcoat™

Min. Distance to Bend

ft (m)

ALL TUBES 10 (3.0)

ALL TUBES 15 (4.6)

ALL TUBES 20 (6.1)

ALL TUBES 25 (7.6)

25 (7.6) ALL TUBES

Doc No 700102 (06-15), Page 16

Page 17

1.8.2 Technical Details - Table 5b (VCT)

No of Injectors

Gas Connection

Electrical Supply

Vent size (in)

Unitary Fan Motor Details

Current Rating

Ignition

Natural Gas LP Gas

MODEL

High / Low

Rate BTU/Hr

100

125

150

60,000/48,000 60,000/48,000

80,000/60,000 80,000/60,000

100,000/75,000 100,000/75,000

123,500/95,000 125,000/95,000

150,000/100,000 150,000/100,000

1.8A MAX (models 60 - 150); 1.0A MAX (models 170 & 200)

High / Low

Rate BTU/Hr

½” N.P.T

120 volt 1 phase 60Hz

4” or 6” (101mm or 152mm)

120 volt 1 phase 60Hz

Electronic Program Start up with Spark Ignition

Min. Heater

Length

Max. Heater

Length

Min. Heater

Length

Max. Heater

Length

S ft (m) S ft (m) U ft (m) U ft (m)

20 40 20 40

30 40 40 40

30 50 40 40

40 60 40 60

170

200

169,000/125,000 169,000/125,000

200,000/160,000

N/A

50 70 60 60

Appliances can be installed up to 10,000ft above sea level in the USA. Altitude conversion kits are available on request.

USA 0- 2000 ft (0-610m) above sea level

Size

Gas

Hi “WC

Lo “WC

60 80 100 125 150 170 200

Natural Gas

3.9 3.5 4.5 4.3 4.0 3.3 4.0

2.6 2.3 3.0 2.7 2.1 1.9 2.5

USA 0- 2000 ft (0-610m) above sea level

Size

Gas

Hi “WC

60 80 100 125 150 170 200

LP Gas

5.5 5.2 8.0 7.6 7.0 6.1 N/A

CANADA 0- 2000 ft (0-610m) above sea level

Size

Gas

Hi “WC

Lo “WC

60 80 100 125 150 170 200

Natural Gas

3.9 3.5 4.5 4.3 4.0 3.3 4.0

2.6 2.3 3.0 2.7 2.1 1.9 2.5

CANADA 0- 2000 ft (0-610m) above sea level

Size

Gas

Hi “WC

60 80 100 125 150 170 200

LP Gas

5.5 5.2 8.0 7.6 7.0 6.1 N/A

Lo “WC

Doc No 700102 (06-15), Page 17

3.5 2.9 4.4 4.6 3.3 3.6 N/A

Lo “WC

3.5 2.9 4.4 4.6 3.3 3.6 N/A

Page 18

Technical Details VCT continued

USA & CANADA Natural Gas 0- 2000 ft (0-610m) above sea level

Size

Burner Orifice Plate Part No.

Flame Plate Part No.

Fan Part No.

Fan Orifice Part No.

Injector Part No.

Injector Carrier Part No.

Pressure Switch Part No.

60 80 100 125 150 170 200

269941 269942 269943 269944 1005513 269946 269946

N/A

270464 270467

269922 269930 269931 266935 269938

269925

270400 270402 270403 270405 270407 270409 270410

270375 270376

270389 270390

USA & CANADA LP Gas 0- 2000 ft (0-610m) above sea level

Size

Burner Orifice Plate Part No.

Flame Plate Part No.

Fan Part No.

Fan Orifice Part No.

Injector Part No.

Injector Carrier Part No.

Pressure Switch Part No.

60 80 100 125 150 170 200 269948 269949 269950 269951 269952 269953 269957 269958 269959 269960

270464 270467 269924 269925 269929 266931 269933 269937 270398 270400 270401 270403

270399

270375 270389

N/A

MODEL

VCT

U20 U40 U60 S20 S30 S40 S50 S60 S70

100

125

150

170

200*

* Nat Gas ONLY

MODEL

VCT

100

125

150

170

200

U Tube Straight Tube

● ●

● ● ●

● ● ● ●

● ● ● ● ●

● ● ● ●

Emitter Tube Type Material

Calcoat™

Min. Distance to Bend

ft (m)

ALL TUBES 10 (3.0)

ALL TUBES 15 (4.6)

ALL TUBES 20 (6.1)

ALL TUBES 25 (7.6)

25 (7.6) ALL TUBES

Doc No 700102 (06-15), Page 18

Page 19

2. Assembly Instructions.

PLEASE READ this section prior to

assembly to familiarize yourself with the components and tools you require at the various stages of assembly. Carefully open the packaging and check the contents against the parts and check list.

The manufacturer reserves the right to alter specifications without prior notice.

2.1 Tools Required.

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Saw

Horses

Cordless Drill

Leather Faced Gloves

5/16” Drive

Please ensure that all packaging is

disposed of in a safe environmentally

friendly way.

For your own safety we recommend the

use of safety boots and leather faced gloves when handling sharp or heavy items. The use of protective eye wear is also recommended.

Suitable alternative tools may be used.

Phillips Screwdriver

3/16” (5mm) 5/32” (4mm) Allen wrench

Wrench Set

Tape Measure

2.2 Assembly Notes.

Please read these assembly notes in

conjunction with the correct assembly drawings (figs 9 to 19).

2.2.1 Emitter Tubes

Each VCS and VCT heating unit has all Calcoat™ emitter tubes.

Position emitter tubes on saw horses. For aesthetics it is advisable to position

seams facing down.

Position coupling fastener so that these cannot be seen from beneath the heater.

Mark out the position of the bracket centers from the dimensions shown on the assembly drawings.

all tube

2.2.2 Turbulator Strips and Burner Inserts

Ensure that the correct turbulator or

burner insert is fitted, as this could void your warranty if they are incorrectly fitted or omitted when necessary.

2.2.2.1 Turbulator Strips

Turbulator strips should be inserted (when required) into the correct emitter tube exactly as indicated in the assembly drawings.

Locate turbulator strip sections. Install the first turbulator strip into the open end of the last emitter tube (only after it has been suspended and connected to the previous emitter tube.)

Interlock the next section of turbulator strip as shown in the diagram below.

Doc No 700102 (06-15), Page 19

Page 20

2.2.2.2

Where a heater configuration requires more than three turbulator strips and has the exhaust heat exchanger tube adjacent to an “L” or “U” heat exchanger tube, refer to the diagram below for positions.

Slide the connected sections into the emitter tube(s). Add further strips to form the correct length required.

For specific configurations see detailed assembly diagrams on pages 25 to 35.

Vent

Model 200 S50 fan orifice plate

This model has a different fan orifice plate (Part No.269939) to all other models in the range. It is supplied with every burner as a loose item and should be discarded if not needed. This must be fitted to the 200 S50 model only.

Note: There should be 22 10mm x 10mm square holes in the replacement plate.

Remove the top cover of the burner to expose the combustion fan.

Remove the four screws (arrowed), three of which can not be seen in the photograph. Lift out the fan assembly to access the fan.

Remove the four fixing screws securing the existing orifice plate, then fit the replacement orifice plate with the correct air inlet hole orientation as shown in the picture opposite.

Fit three turbulator strips here

Vent

Fit the remaining turbulator strips here

Doc No 700102 (06-15), Page 20

Page 21

2.2.2.2 Burner Inserts

The burner insert (when required) is inserted into the first emitter tube from where it is joined to the second emitter tube.

2.2.3 Brackets

There can be various styles of brackets supplied with these heaters:

2.2.3.1 Suspension Brackets

2.2.3.1.1 Fixed suspension bracket assembly part #270130 & tube straps part #270571.

ONLY used as the first suspension bracket

positioned CLOSEST TO THE BURNER.

SUSPENSION BRACKET

RADIANT TUBE

PART #270130

2.2.3.2 Reflector Support Brackets

Reflectors are positioned above the emitter tube with a reflector support bracket part #270570.

RADIANT

TUBE

STRAP

SUPPLIED

NUT &

BOLT

SUPPLIED

NUT & BOLT

RADIANT TUBE

"A"

VIEW ON "A"

PARTS #270130 plus #270571

TUBE

STRAP

Slip the suspension first bracket assembly part #270130 onto the first section of emitter tube in the position as indicated on the assembly drawing.

Locate the tube strap assembly part #270571 and loosen the nut and bolt.

Position the strap over the emitter tube and hook the two straps onto the suspension bracket.

Finally tighten the nut and bolt to secure the bracket onto the emitter tube.

2.2.3.1.2 Suspension brackets #270130 with no tube straps. For

ALL other suspension

brackets

Once the emitter tubes have been assembled using the couplers (see section 2.2.4), position all other suspension brackets part #270130 onto the tube(s) in their relevant positions as shown on the assembly drawing.

REFLECTOR BRACKET #270570

Locate a suspension support bracket and remove the bolt fixing the strap to the bracket.

Position the bracket over the emitter tube and loosely replace the bolt.

Roughly position the support brackets in place along the emitter tube assembly as indicated on the assembly drawing. The positioning may need to be adjusted when the reflector is added.

2.2.4 Couplers

The couplers are used for joining radiant tubes and U or L bends.

Slide the coupler over the emitter tube ensuring that the rivet stop has butted up to the emitter tube ends.

Doc No 700102 (06-15), Page 21

Page 22

Using the Allen wrench, tighten the pins.

DO NOT OVERTIGHTEN.

Moving between the two set pins, tighten both ensuring that equal pressure is applied to each set pin in turn. Complete assembly by drilling and screwing self tapping retention zip screws.

At this point raise the tube assembly into

position and suspend from previously fixed chains (Working Load 100lb). Longer tube assemblies may be raised in more than one sub-assembly with the final emitter tube connection made in the air.

2.2.5 Reflectors.

All reflectors must be positioned/ attached to the brackets exactly as detailed in the assembly drawings.

After removing the coloured protective plastic coating (where fitted), slip the reflectors through the suspension brackets until they overlap each other.

The first two reflectors are assembled and overlapped by a pre determined distance, as shown on the assembly drawing, and are fixed onto the emitter tube using the reflector support bracket part #270570.

Each reflector must OVERLAP the previous one as indicated by their individual assembly sheets.

(TWISTED LINK, PLATED)

NOTE. HOOKS ARE TO BE CLOSED UP AFTER ASSEMBLY

2/0 GA CHAIN

Reflectors. Note: each reflector must overlap the previous one

Reposition the reflector support bracket if necessary then tighten the clamp bolt.

These two reflectors are fixed in place by tightening the fixing screws/locknuts as below. These are known as ‘non-slip’ overlaps.

TIGHTEN SCREWS TO FIX REFLECTOR

The next reflector is assembled and overlapped by the pre determined distance. The reflector is fitted onto the emitter tube using another reflector support bracket part #270570.

Reposition the reflector support bracket if necessary, then tighten the clamp bolt.

These overlapped reflectors are allowed to ‘float’ within the support bracket by leaving a minimum of 1/8” gap of the fixing screws before tightening the locknuts. These are known as ‘slip’ overlaps.

1 8

" min

ALLOW REFLECTOR TO SLIDE

LEAVE

" MIN GAP TO

Further reflectors are assembled and overlapped onto the emitter tube by alternating ‘non-slip’ and ‘slip’ until complete length is covered.

Continue this method to the final reflector/ support bracket.

See stetch below for typical ‘slip’ and ‘non-slip’.

Further reflectors to be

overlapped in the same method

Burner

Suspension Bracket

part #270130

and fixing #270571

Doc No 700102 (06-15), Page 22

Support Bracket

part #270570

non-slip overlap

Support Bracket

part #270570

slip overlap

Support Bracket

part #270570

non-slip overlap

Subsequent support brackets to

be alternatin

'slip' and 'non-slip'

Page 23

2.2.6 End Caps (optional)

Position an end cap beneath the reflector profile (where required) with the end cap flanges facing inwards. Fasten to reflector using the four ’Z’ clips.

16” crs

Note: For high wind/outdoor applications use additional drill screws to secure end cap

to the reflector.

End

2.2.7 Bend(s) (where fitted)

The heater can be installed with 1 or 2 90° bends or a 180° U bend.

Slide the bend into the open end of the coupler ensuring that the screw stop has butted up to the emitter tube ends. Refer to 2.2.4 for fastening.

90° Elbow

Corner reflector

90° Bend

2.2.8 Burner/Fan Assembly.

Slide the burner assembly onto the open emitter tube end, ensuring it is fully engaged. Secure with set screws.

For the purpose of unvented applications, a 4” 90° elbow should be used on the terminating end of the radiant tube sections and completed using a vent cap.

Connect Gas and Electrical supplies as described in sections 1.4 and 1.5.

2.2.9 Detailed Assembly Drawings

End Caps

The following pages show the technical dimensional details for the range of heaters available.

Please note the heater type, length and reference number from the delivery/advice note before identifying the correct model drawing.

Corner reflector kit

End Caps

U Bend

15”

Doc No 700102 (06-15), Page 23

Page 24

Figure 8. Possible Heater Orientations

S20

S30

S40

S50

S60

Bends must be fitted at a distance of at least 50% of the total heat exchanger

e.g. for a 60ft long heater, the closest to the burner a bend can be is 30ft.

S70

S80

U20

U40

U60

U80

Doc No 700102 (06-15), Page 24

Page 25

Figure 9. Heater Assembly: Model Linear VCS 60-S20, VCT 60-S20.

END CAPS

(OPTIONAL)

PART #270130

SUSPENSION BRACKET

6"-9" REFLECTOR OVERLAP

REFLECTOR SUPPORT

TURBULATOR(S)

(SEE DETAIL)

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

PART #270125

QTY 1 REQUIRED

STAINLESS 4" COUPLER

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #116019

QTY 3 REQUIRED

TURBULATOR SECTION

21'6½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

NO TO EXCEED 12'

DISTANCE BETWEEN

SUSPENSION POINTS

10' 3" REFLECTORS TYPICAL OF 2

PART #270130 PLUS

STRAP PART #270571

END CAPS

(OPTIONAL)

COUPLER

(SEE DETAIL)

BURNER INSERT

BRACKET PART #270570

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

QTY 2 REQUIRED

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

PART #270489 (5FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED NAT GAS ONLY

PART #270570

QTY 2 REQUIRED

REFLECTOR SUPPORT BRACKET

BURNER

Doc No 700102 (06-15), Page 25

ASSEMBLY OVERVIEW

DETAILS

Page 26

Figure 10. Heater Assembly: Model Linear VCS 60-S30, 80-S30, 100-S30, 125-S30. VCT 60-S30, 80-S30, 100-S30, 125-S30.

END CAPS

(OPTIONAL)

PART #270130

SUSPENSION BRACKET

6" REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

6" REFLECTOR OVERLAP

COUPLER

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

STAINLESS 4" COUPLER

PART #270125

QTY 2 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #116019

TURBULATOR SECTION

QTY 5 REQUIRED SIZE 125 ONLY

QTY 3 REQUIRED SIZE 80/100 ONLY

QTY 4 REQUIRED SIZE 100 LPG ONLY

31'6½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

DISTANCE BETWEEN

PART #270130 PLUS

SUSPENSION BRACKET

PART #270130

NO TO EXCEED 12'

SUSPENSION POINTS

STRAP PART #270571

END CAPS

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

COUPLER TURBULATOR

(SEE DETAIL)

BURNER INSERT

10' 3" REFLECTORS TYPICAL OF 3

(OPTIONAL)

BURNER

ASSEMBLY OVERVIEW

DETAILS

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

BRACKET PART #270130

PART #270130 plus STRAP #270571

QTY 3 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270489 (5FT)

BURNER INSERT DETAIL

PART #270570

REFLECTOR SUPPORT BRACKET

QTY 1 REQUIRED SIZE 60-100 NG ONLY

QTY 3 REQUIRED

PART #1005500 (3FT)

QTY 1 REQUIRED SIZE 125 NG ONLY

Doc No 700102 (06-15), Page 26

Page 27

Figure 11. Heater Assembly: Model Linear VCS 60-S40, 80-S40, 100-S40, 125-S40, 150-S40. VCT 60-S40, 80-S40, 100-S40, 125-S40, 150-S40.

END CAPS

(OPTIONAL)

41'6½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

PART #270130

3" REFLECTOR

PART #270130

6" REFLECTOR

PART #270130

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

TURBULATOR

(SEE DETAIL)

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

COUPLERCOUPLERCOUPLER

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

PART #270125

STAINLESS 4" COUPLER

QTY 3 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 125/150 ONLY

6" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

TYPICAL OF 4

10' 3" REFLECTORS

PART #270130 PLUS

STRAP PART #270571

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

BURNER

Doc No 700102 (06-15), Page 27

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

BURNER INSERT

ASSEMBLY OVERVIEW

DETAILS

QTY 4 REQUIRED

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

PART #270489 (5FT)

PART #1005500 (3FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 125 NG ONLY

QTY 1 REQUIRED SIZE 60-100 NG ONLY

PART #270570

QTY 4 REQUIRED

REFLECTOR SUPPORT BRACKET

Page 28

Figure 12. Heater Assembly: Model Linear VCS 100-S50, 125-S50, 150-S50, 170-S50, 200-S50. VCT 125-S50, 150-S50, 170-S50, 200-S50.

END CAPS

(OPTIONAL)

2" MINIMUM

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

NOTE: The 200 S50 model

requires a different fan orifice

plate. See P20 for details.

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

DETAIL

REFLECTOR SUPPORT BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

51'6½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

COUPLER COUPLER COUPLER COUPLER

PART #270125

STAINLESS 4" COUPLER

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

QTY 4 REQUIRED

QTY 5 REQUIRED

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 200 NG ONLY

PART #270489 (5FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 100 NG ONLY

QTY 2 REQUIRED SIZE 170 LPG ONLY

PART #1005500 (3FT)

QTY 1 REQUIRED SIZE 125 NG ONLY

TYPICAL OF 5

10' 3" REFLECTORS

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270130 PLUS

STRAP PART #270571

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

BURNER

Doc No 700102 (06-15), Page 28

(SEE DETAIL)

BURNER INSERT

PART #270570

QTY 5 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

ASSEMBLY OVERVIEW

DETAILS

REFLECTOR SUPPORT BRACKET

Page 29

Figure 13. Heater Assembly: Model Linear VCS 125-S60, 150-S60, 170-S60, 200-S60. VCT 150-S60, 170-S60, 200-S60.

END CAPS

(OPTIONAL)

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

SLIP REFLECTOR OVERLAP

PART #270125

QTY 5 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

STAINLESS 4" COUPLER

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

61'6½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

6" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

TYPICAL OF 6

10' 3" REFL'S

PART #270130 PLUS

STRAP PART #270571

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700102 (06-15), Page 29

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

QTY 6 REQUIRED

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

REFLECTOR SUPPORT

BRACKET PART #270570

COUPLER COUPLER COUPLER COUPLER COUPLER

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

BURNER INSERT

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

ASSEMBLY OVERVIEW

BURNER

DETAILS

PART #1005500 (3FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 125 NG ONLY

PART #270570

QTY 6 REQUIRED

REFLECTOR SUPPORT BRACKET

Page 30

Figure 14. Heater Assembly: Model Linear VCS 150-S70, 170-S70, 200-S70. VCT 170-S70, 200-S70.

END CAPS

(OPTIONAL)

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

PART #270125

QTY 6 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

STAINLESS 4" COUPLER

OVERLAP

71'6½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

PART #270130 PLUS

SUSPENSION BRACKET

STRAP PART #270571

6" REFLECTOR

OVERLAP

END CAPS

10' 3" REFL'S

(OPTIONAL)

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

QTY 7 REQUIRED

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

REFLECTOR SUPPORT

BRACKET PART #270570

COUPLER COUPLER COUPLER COUPLER COUPLER COUPLER

TYPICAL OF 7

BURNER

NON-SLIP REFLECTOR OVERLAP

PART #270570

QTY 7 REQUIRED

QTY 1 REQUIRED OF EACH

ASSEMBLY OVERVIEW

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

DETAILS

REFLECTOR SUPPORT BRACKET

Doc No 700102 (06-15), Page 30

Page 31

Figure 15. Heater Assembly: Model Linear VCS 170-S80 and 200-S80.

END CAPS

(OPTIONAL)

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

NON-SLIP REFLECTOR OVERLAP

STAINLESS 4" COUPLER

PART #270125

QTY 7 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

81'6½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270130

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

COUPLER COUPLER COUPLER COUPLER COUPLER

QTY 8 REQUIRED

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

PART #270130

SUSPENSION BRACKET

TYPICAL OF 8

10' 3" REFL'S

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270130 PLUS

STRAP PART #270571

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

COUPLER

REFLECTOR SUPPORT

BRACKET PART #270570

COUPLER

BURNER

NON-SLIP REFLECTOR OVERLAP

ASSEMBLY OVERVIEW

DETAILS

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

BRACKET PART #270130

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

PART #270570

REFLECTOR SUPPORT BRACKET

QTY 8 REQUIRED

Doc No 700102 (06-15), Page 31

Page 32

Figure 16. Heater Assembly: Model U tube VCS 60-U20, VCS 80-U20. VCT 60-U20.

2" MINIMUM

3' 3"

DETAIL

REFLECTOR SUPPORT BRACKET

BRACKET PART #270570

(SEE DETAIL)

SUSPENSION POINTS

NO TO EXCEED 12'

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

PART #270130

SUSPENSION BRACKET

STAINLESS 4" COUPLER

PART #270125

QTY 2 REQUIRED

TURBULATOR SECTION

PART #116019

QTY 1 REQUIRED SIZE 60 ONLY

QTY 3 REQUIRED SIZE 80 VCS ONLY

BRACKET PART #270570

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

PART #270130

COUPLERS

SUSPENSION BRACKET

BURNER INSERT

DISTANCE BETWEEN

12'1½" NOMINAL OVERALL ASSEMBLED LENGTH

TURBULATOR

(SEE DETAIL)

10' 3" REFLECTORS TYPICAL OF 2

PART #270130

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700102 (06-15), Page 32

BURNER

PART #270130 PLUS

STRAP PART #270571

SUSPENSION BRACKET

ASSEMBLY OVERVIEW

DETAILS

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

QTY 3 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270489 (5FT)

BURNER INSERT DETAIL

PART #270570

REFLECTOR SUPPORT BRACKET

QTY 1 REQUIRED NAT GAS ONLY

QTY 2 REQUIRED

Page 33

Figure 17. Heater Assembly: Model U tube VCS 60-U40, 80-U40, 100-U40, 125-U40 and 150-U40. VCT 60-U40, 80-U40, 100-U40, 125-U40 and 150-U40.

3' 3"

SLIP REFLECTOR OVERLAP

BRACKET PART #270570

REFLECTOR SUPPORT

PART #270130

SUSPENSION BRACKET

BRACKET PART #270570

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

COUPLERS

BRACKET PART #270570

REFLECTOR SUPPORT

PART #270130

SLIP REFLECTOR OVERLAP

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

SUSPENSION BRACKET

SUSPENSION POINTS

DISTANCE BETWEE N

NO TO EXCEED 12'

6"-9" REFLECTOR OV ERLAPS

COUPLERS

BRACKET PART #270570

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

PART #270125

STAINLESS 4" COUPLER

QTY 4 REQUIRED

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 150 ONLY

22'1½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270130

SUSPENSION BRACKET

TURBULATOR

PART #270130

SUSPENSION BRACKET

END CAPS

PART #270130

SUSPENSION BRACKET

(SEE DETAIL)

10' 3" REFLECTORS TYPICAL OF 4

BURNER INSERT

SUSPENSION BRACKET

STRAP PART #270571

PART #270130 PLUS

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

QTY 5 REQUIRED

PART #270489 (5FT)

BURNER INSERT DETAIL

PART #1005500 (3FT)

QTY 1 REQUIRED SIZE 125 NG ONLY

QTY 1 REQUIRED SIZE 60-100 NG ONLY

(OPTIONAL)

BURNER

PART #270570

QTY 4 REQUIRED

QTY 1 REQUIRED OF EACH

ASSEMBLY OVERVIEW

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

DETAILS

REFLECTOR SUPPORT BRACKET

Doc No 700102 (06-15), Page 33

Page 34

Figure 18. Heater Assembly: Model U tube VCS 125-U60, 150-U60, 170-U60 and 200-U60. VCT 150-U60, 170-U60, 200-U60.

3' 3"

2" MINIMUM

REFLECTOR SUPPORT

BRACKET PART #270570

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

DETAIL

32'1½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270130

SUSPENSION BRACKET

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

PART #270130

SUSPENSION BRACKET

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

COUPLERS

PART #270130

SUSPENSION BRACKET

6" REFLECTOR OVERLAPS

6"-9" REFLECTOR OVERLAPS

COUPLERS

REFLECTOR SUPPORT

COUPLERS

REFLECTOR SUPPORT

SLIP REFLECTOR OVERLAP

BRACKET PART #270570

PART #270130

SUSPENSION BRACKET

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

STAINLESS 4" COUPLER

PART #270125

QTY 6 REQUIRED

REFLECTOR SUPPORT BRACKET

PART #270130

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION

POINTS NO TO EXCEED 12'

PART #270130

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700102 (06-15), Page 34

10' 3" REFLECTORS TYPICAL OF 6

BURNER

(SEE DETAIL)

BURNER INSERT

SUSPENSION BRACKET

PART #270130

STRAP PART #270571

PART #270130 PLUS

ASSEMBLY

OVERVIEW

QTY 7 REQUIRED

BURNER INSERT DETAIL

REFLECTOR SUPPORT BRACKET

PART #1005500 (3FT)

PART #270570

QTY 1 REQUIRED SIZE 125 NG ONLY

QTY 6 REQUIRED

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

BRACKET PART #270130

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

DETAILS

Page 35

Figure 19. Heater Assembly: Model U tube VCS 170-U80 and 200-U80.

3' 3"

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

PART #270130

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

COUPLERS

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270570

PART #270130

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

6" REFLECTOR OVERLAPS 3" REFLECTOR OVERLAPS6"-9" REFLECTOR OVERLAPS

COUPLERS COUPLERS

REFLECTOR SUPPORT

BRACKET PART #270570

PART #270125

SLIP REFLECTOR OVERLAP

QTY 8 REQUIRED

STAINLESS 4" COUPLER

42'1½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270130

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION

PART #270130

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

POINTS NO TO EXCEED 12'

10' 3" REFLECTORS TYPICAL OF 8

BURNER

COUPLERS

PART #270130

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270570

NON-SLIP REFLECTOR OVERLAP

PART #270130

SUSPENSION BRACKET

STRAP PART #270571

PART #270130 PLUS

ASSEMBLY

OVERVIEW

QTY 9 REQUIRED

BRACKET PART #270130

TUBE & REFLECTOR SUSPENSION

PART #270570

QTY 8 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270130 plus STRAP #270571

FIRST SUSPENSION POINT BRACKET

REFLECTOR SUPPORT BRACKET

DETAILS

Doc No 700102 (06-15), Page 35

Page 36

3. Start Up Instructions.

These appliances should be commissioned by a qualified mechanical contractor.

3.1 Tools Required.

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Leather Faced Gloves

Phillips Screwdriver

Suitable alternative tools may be used.

Small Flat Head Screwdriver

Large Adjustable Wrenches for fitting Of Gas Flex.

½” Wrench

5/32” (4mm) Allen Wrench

3.2 Start Up procedure

Inspect installation and ensure that it has been carried out in accordance with these instructions. Ensure that electrical and gas supplies are isolated.

The gas supply should be purged and tested for soundness in accordance with local and National Safety codes.

Open isolating gas valve and test gas connections for soundness using soap solution.

Open the control housing door by unscrewing the securing screw. Ensure all internal components are securely fixed and all connections securely made.

Switch on the electrical supply to start the heater and observe the correct start up sequence. Ensure that the setting of any time switch and thermostat are such that the heating system will be required to operate.

The fan will start to run and the ‘power on’ lamp will illuminate. Safe-start checks are carried out automatically.

After the fan has run up to full speed and a satisfactory pressure condition has been established, the ignition sequence will commence. The spark ignition will be energized producing a spark at the ignition electrode. The gas solenoid valve will at the same time be energized and the ‘burner on’ lamp will illuminate. If the ignition is successful the flame is detected by the flame sensing probe and the ‘burner on’ lamp will remain on.

If ignition is unsuccessful the gas valve will close and the spark ignition de-energized after approximately 10 seconds.

For approximately 30 seconds the fan will purge the system then re-ignition will be attempted. After 2 further attempts at ignition the control unit will ‘lock-out’, the ‘power on’ lamp will remain illuminated and the fan will continue to run.

To reset after ‘lockout’ switch off the power supply to the system and wait 2 minutes. Then turn the power on. If repeated ‘lockout’ occurs investigate the cause.

Set burner gas pressure as follows: Switch off the power supply to the heating system.

Connect a ‘U’ tube manometer to the pressure test point provided on the combination gas control valve.

Remove the cover from the pressure regulator revealing the adjustable screw.

Start the heater and using a suitable screwdriver adjust the pressure regulator, turning the screw clockwise to increase the pressure or counter-clockwise to decrease the pressure.

Set the pressure to appropriate inches w.c. from the table of gas pressures and orifice plate dimensions for correct heater description. (See section 1.8 page 15 for VCS or page 17 for VCT)

Manometer

Multimeter

Doc No 700102 (06-15), Page 36

Page 37

VCT ONLY: The high fire gas pressure should be set first followed by the low fire gas pressure. Re-check the high fire and re-adjust if necessary.

To enable post purge ensure that the setting of any time switch and thermostat are such that the heating system will be required to turn off.

Switch off the power supply to the heating system. Disconnect ‘U’ tube manometer, then secure screw in pressure test nipple.

Check the operation of the flame safeguard equipment as follows:

With the heater running normally, switch off the gas supply at the shut off valve. The heater should attempt to relight. If the gas valve has been left off, ‘lock-out’ should occur. This is indicated by the ‘power on’ lamp being illuminated and fan running, but the ‘burner on’ lamp being off.

Check the operation of the pressure proving switch as follows:

With the heater running normally, pull off the silicone rubber tube connecting the vacuum switch to the combustion chamber. Within 4 seconds the burner should shut off.

Then replace the tube securely and observe that the heater proceeds to ignite in the normal way.

Close the controls door securing it with the screw.

Doc No 700102 (06-15), Page 37

Page 38

Commissioning chart

Check installation has

been carried out to these

instructions.

Remove burner from tube and inspect burner head.

Replace burner on tube

and secure.

Check thermostat is set to

maximum and is calling

for heat.

Ensure gas and electricity

supplies are isolated.

(See servicing instructions)

Reconnect gas hose.

Open Manual valve.

Check soundness.

Switch on electrical supply.

The red neon should now

be illuminated. If restarting

heater a delay of 15sec

should be allowed.

Disconnect gas hose from

burner

Open control housing and check that all components

are securely fastened.

The heater should now run through its start up

sequence and ignite.

Check gas pressure.

Leave the instructions

with a responsible person.

A successful ignition is indicated

by the amber light illuminating

and remaining illuminated.

Close control housing

Turn off power and check

that all components are

securely fastened.

Has the

burner lit?

YES

Check operation on flame failure.

Check gas pressure.

Check operation of

air pressure switch.

Doc No 700102 (06-15), Page 38

Page 39

4. Servicing Instructions.

These appliances should be serviced annually by a competent person to ensure safe and efficient operation. In mildly dusty or polluted conditions more frequent servicing

may be required. Servicing work should be carried out by a qualified mechanical contractor.

4.1 Tools Required.

The following tools and equipment are advisable

Leather Faced Gloves

½” Wrench

4.2 Burner Description.

Figure 20. Burner breakdown

Flame Plates (Q)

269960 170 LP

269959 125/150 LP

Phillips Screwdriver

5/32” (4mm) Allen Wrench

to complete the tasks laid out in this manual.

Suitable alternative tools may be used.

Small Flat Head Screwdriver

Manometer

Multimeter

Large Adjustable wrenches for fitting of Gas Flex.

Note: Cables Omitted For Clarity

Soft Brush

269958 80/100 LP

269957 60 LP

Part Number

A Ignition Controller 204955

B Gas Valve (VCS)

(VCT)

C Power On Red LED 270466

D Burner On Yellow LED 270465

E High Fire Yellow LED

(VCT ONLY)

F Burner Tube 270424

G Burner head 270425

H Injector See section 1.8 P15 & 18

Doc No 700102 (06-15), Page 39

270378 (NG) 270496 (LP) 270373 (NG) 270498 (LP)

270465

Square section not on VCS models

Part Number

I Igniter Assembly 270441

J Injector Carrier

K Combustion Fan

L Pressure Switch

M Gaskets

N Transformer (VCS)

(VCT)

O 24V Relay (VCT) 270472

P Burner Orifice Plate

Q Flame Plate (not shown)

See section 1.8 P15 & 18

2 off 270366

175265 194808

See section 1.8 P15 & 18

See photos above

Page 40

4.3 Burner Removal

Step 1: Isolate power and gas supplies.

Step 2: Disconnect the external power/control

connections.

Step 6: Remove the burner and position the

burner in a safe area to prevent the burner or components attached to the burner from falling to the ground.

Step 3: Detach the gas supply as shown

below, taking care to support the burner connection.

4.4 Burner Gas Injector Servicing

Step 1:

Remove the 4 retaining screws, then

remove the burner support casting and gasket.

Step 4: If ducted air is connected, loosen hose

clip and remove the flexible hose from the burner.

Step 5: Loosen the set screw on the burner

support casting to enable the burner to be removed from the radiant tube.

Doc No 700102 (06-15), Page 40

Step 2: The burner head assembly can be

disconnected by separating the connectors of the ignition lead assembly and removing the earth lead and pressure switch silicon tube.

Page 41

Step 3: The gas injector can be inspected and

replaced if contaminated or blocked.

When replacing the gas injector ensure approved thread sealant is used.

Step 4: Reconnect ignition leads and silicone

tube to test nipple. Refit gasket and support casting.

4.5 Combustion Fan Servicing

Step 1: Remove the four top lid screws to

reveal the combustion fan shown below.

Step 4: Remove fan orifice plate.

Step 5: Inspect the impeller and remove any

dust with a soft brush.

Step 6: Remove any dust from fan scroll and

from around the motor.

Step 7: Ensure the impeller rotates freely.

Step 8: Refit components.

Step 2: Disconnect the fan cables after first

noting their positions, then pull cable through to fan compartment.

4.6 Burner Head and Electrode Servicing

Step 1:

Check the pepper pot burner head for contamination. If necessary this can be removed. See below.

Step 3: Remove the four fan fixing screws then

withdraw the fan complete with mounting bracket as shown below.

Doc No 700102 (06-15), Page 41

This can be cleaned together with the inside of the burner head.

Step 2: The pepper pot burner head can be

replaced ensuring the 5 holes on the outer ring are aligned alongside the probes.

Step 3: The condition of the igniter assembly

can be checked for deterioration. However, we advise replacement at each service to ensure

Page 42

continued reliability. Detach the electrode assembly from the burner head by removing the two screws as shown and separating the igniter assembly lead connectors.

Step 4: Refit the electrode assembly and

ensure the connections are secure to prevent incorrect sparking of the spark electrode.

Step 5:

Check the positions and spark gap as

shown in diagram below.

Step 6: The burner assembly is ready to refit

after servicing the combustion fan and the radiant tube assembly.

Step 7: Refit components.

4.7 Emitter Tube Servicing

Step 1:

Brush any dust from the exterior of the

emitter tubes.

Step 2: Inspect the fan and emitter tubes

visually. If the tubes appear clean, skip to servicing the reflector.

Step 3: If required the interior of the emitter

tubes can then be cleaned using an industrial vacuum cleaner or by using long poles and a scraper.

4.8 Reflector Servicing

The condition of the reflectors should be noted. If necessary the reflectors can be cleaned with a mild detergent. This can significantly improve the efficiency of the appliance.

4.9 Cleaning of Vent

Inspect the fresh air inlet duct and vent to ensure they are free from any blockage or obstruction. The air inlet terminal and vent terminal should be inspected to ensure they are not liable to obstruction.

4.10 Re-commissioning After Service

After servicing of the heater has been undertaken, it will be necessary to re-commission the heater as detailed in the commissioning chart in these instructions.

Doc No 700102 (06-15), Page 42

Page 43

5. Troubleshooting Guide.

START

Ensure gas & electricity

supplies are enabled.

Turn any external timer

to call for heat (if fitted).

Does the Power On

light illuminate?

YES

CHECK: -

1. Operation of any timer or control.

2. External fuses.

3. Voltage is 120VAC.

Is there power to the

burner?

CHECK: -

1. Internal fuse.

YES

2. Integrity of wiring connections.

3. Light.

YES

Set two-stage thermostat to

call for heat at maximum

setting (High Fire).

Does the fan run? NO

Do the amber

lights illuminate after a

purge period?

Is there power to the

fan?

CHECK: -

1. Relays 2 & 3.

2. Voltage across terminals A1 & A2 is 24VAC for relay 2 & 3.

3. Integrity of wiring connections.

4. Pressure switch operation.

5. Ignition controller.

Does the pressure

switch close?

YES

CHECK: -

1. Voltage supply to fan terminal F2 is 120VAC.

2. Integrity of wiring connections.

3. Fan.

CHECK: -

1. Pressure switch wiring connections.

2. Relay 1.

3. Voltage across relay 1 terminals A1 & A2 is 120VAC.

4. Integrity of wiring connections.

5. Amber lights.

6. Ignition controller.

YES

Doc No 700102 (06-15), Page 43

CHECK: -

1. Hose connection to pressure switch.

2. Air inlet, outlet, and emitter tubes for obstructions.

3. Pressure switch operation.

4. Supply voltage 120VAC.

Page 44

To aid in the trouble shooting process the UT controller has a LED flash code diagnostic sequence:

Steady Off No control Power Steady On Power Applied, Control OK 1 Flash Combustion Pressure Switch Open With Blower On 2 Flash Combustion Pressure Switch Closed With Blower Off 3 Flash Lockout From The Three Ignition Trials 4 Flash Lockout From Five Flame Losses 5 Flash Control Hardware Fault Detected 6 Flash Lockout From Five Pressure Switch Losses

Doc No 700102 (06-15), Page 44

Page 45

6. Replacing Parts.

Turn off gas and any electrical supplies to the heater before starting repair work.

6.1 Burner Controller Replacement

Step 1:

bottom access door.

Step 2: Disconnect burner controller from the

wiring harness.

Remove the four screws securing the

Step 2: Remove the two electrical chassis

retaining screws arrowed.

Step 3: Disconnect the Spark Lead from burner

controller.

Step 4: Remove burner controller from its

retaining screws and remove.

Step 5: Fit new burner controller.

Step 6: Refit spark lead and wiring harness

connector.

Step 7: Test product and close access door.

6.2 Air Pressure Switch Replacement

Step 1:

the pressure switch.

Disconnect the two silicone tubes from

Step 3:

It may be necessary to partially disconnect the chassis wiring to access the pressure switch mounting screws at the rear.

Disconnect pressure switch wiring.

Doc No 700102 (06-15), Page 45

Page 46

Step 4: Turn chassis over and remove the two

pressure switch retaining screws.

Step 4: Remove the gas valve wiring

connections, noting their positions.

Step 5: Fit the new air pressure switch in

reverse order ensuring the silicone tubes are connected as shown below.

Step 6: Re-connect wiring.

Step 7: Test product and close access door.

6.3 Gas Valve Replacement

Step 1:

Remove the burner assembly as

described in the Servicing section.

Step 2: Open the rear access door.

Step 3: Remove the two securing screws

(arrowed) from the base of the injector tube, noting earth terminal connection.

Doc No 700102 (06-15), Page 46

Step 5: Remove the four screws (arrowed)

securing the gas valve inlet plate to the burner housing and remove plate.

Step 6: Remove gas valve rearwards as shown.

Step 7: The jet carrier and gas inlet can now be

detached from the gas valve.

Step 8: Replace gas valve and Re-connect

wiring.

Step 9: Set burner pressure.

Step 10: Test product and close access door.

Page 47

Notes.

Doc No 700102 (06-15), Page 47

Page 48

7. User & Operating Instructions.

Radiant tubular infrared heaters are designed for overhead heating of industrial and commercial buildings. Individual heating units are suspended from the roof installer.

1. This appliance must only be installed by qualified in accordance with the requirements of local and National Codes.

2. This appliance must be grounded in accordance with the National Electrical Code ANSI/NFPA No.70 or Canadian Codes.

3. Never rest anything, especially ladders against the heaters.

7.1.1 To Start the VCS Heater

1. First ensure that the gas supply to each heater is turned on by opening the main gas shut off valve.

2. Ensure that the setting of any time clock and thermostat are such that the heating system will be required to operate.

3. Switch on the electricity supply to the heater. The fan will start, the ‘power on’ light on the burner will illuminate and ignition commence.

4. Ignition will occur.

5. If ignition is unsuccessful the gas valve will close and the spark ignition de-energize after approximately 15 seconds. For approximately 30 seconds the fan will purge the system then re-ignition will be attempted. After 3 attempts at ignition the control unit will ‘lock-out’, the ‘power on’ lamp will remain illuminated and the fan will continue to run for 120 seconds then stop. To reset after ‘lockout’, switch off the power supply to the heater and wait 5 minutes. Then turn the power on. If repeated ‘lockout’ occurs investigate the cause.

7.1.2 To Start the VCT Heater

1. First ensure that the gas supply to each heater is turned on by opening the main gas shut off valve.

2. Switch on the electrical supply to the heater. The ‘power on’ lamp will illuminate.

3. Ensure that the settings of the two stage thermostat and any time switch are set so

that the heating system will be required to operate.

4. The fan will start and the ignition sequence will commence.

5. Ignition of the burner will occur and the ‘low fire’ light only will illuminate for low fire and both the ‘low fire’ and ‘high fire’ lights will illuminate for high fire.

6. If ignition is unsuccessful the gas valve will close and the spark ignition de-energize after approximately 15 seconds. For approximately 30 seconds the fan will purge the system then re-ignition will be attempted. After 3 attempts at ignition the control unit will ‘lock-out’, the ‘power on’ lamp will remain illuminated and the fan will continue to run for 120 seconds then stop. To reset after ‘lockout’, switch off the power supply to the heater and wait 5 minutes. Then turn the power on. If repeated ‘lockout’ occurs investigate the cause.

7.2. To Switch Off Heater

Ensure that the setting of any time switch

and thermostat are such that the heating system will be required to turn off. Switch off electrical supply to the heater. The burner will stop and the fan will shut off.

7.3. Servicing

To ensure continued, efficient and safe operation it is recommended that the heater be serviced regularly by a qualified person every year in normal working environments but in exceptionally dusty or polluted environments more frequent servicing may be needed.

Doc No 700102 (06-15), Page 48

Specifications & illustrations subject to change without notice or incurring obligations. © Nortek Global HVAC, LLC 2015, All rights reserved. Printed in U.S.A. (06-15) All trade marks are the property of their respective organizations.

Doc No. 700102

Reznor VCS100 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual