Reznor VPS, VPS 60, VPS 80, VPS 100, VPS 125 Installation & Operation Manual

...
INSTALLATION / OPERATION / MAINTENANCE
Applies to: Model VPS 120V 60Hz
Gas-Fired, Tubular, Radiant,
Low-Intensity Infrared Heater
Model VPS Burner/Control Box with 20 - 80 ft Tube/Reflector Length
Introduction.
Welcome to the new range of powered infra-red 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 and servicing is undertaken on radiant tube
Document Index.
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.
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
1.6 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 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
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 Radiant Tube Servicing
4.8 Reflector Servicing
4.9 Cleaning of Vent
4.10 Re-commissioning after Service
5 Spare Parts 6 Troubleshooting Guide 7 Replacing Parts
7.1 Burner Controller Replacement
7.2 Air Pressure Switch Replacement
7.3 Gas Valve Replacement
7.4 Optional Extra Kits
8 User and Operating Instructions
8.1 To Start Heater
8.2 To Switch Off Heater
8.3 Servicing
1. Installation Requirements.
1.1 Health and Safety
A. Heater is intended for heating
non-residential indoor spaces and should only be installed where flammable gases or vapors are not generally present.
B. Heaters may be suspended either
horizontal or at any angle. See section
1.3 for clearance dimensions.
C. The installation must 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 Natural Gas and Propane Installation Code, CSA B149.1.
D. The unit shall be electrically grounded in
accordance with National Electric Code ANSI/NFPA 70 and Canadian Electrical Code CSA C22.1.
E. The heater may be installed in aircraft
hangars in accordance with the Standard
for Aircraft Hangars, ANSI/NFPA 409
and in automotive garages when
2
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) for the US and 0 - 4500 ft (1370m) for Canada. Conversion kits are available on installations above these heights in the USA.
1.2 Heater Suspension
Attachment to the heater support lugs should be made by D shackle. The hanging attachments to overhead steelwork etc. must be purpose made to sound engineering practice or supplied by others.
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 tube/ bracket/reflector has been completed. Longer tube assemblies may be raised in more than one sub-assembly with final tube connection made in the air.
The suggested mounting heights for heaters are given in the chart next page.
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.
Figure 1. Recommended Methods of Heater Suspension.
U TUBE VARIANTS
EYE HOOKS
NOTE. HOOKS ARE TO
BE CLOSED UP AFTER ASSEMBLY
Suitable Chain
2/0 GA CHAIN
Working Load Limit
(TWISTED LINK, PLATED)
100lb.
EXHAUST
END
CHAIN
55° SUSPENSION
3
BURNER
END
ON U TUBE VARIANTS THE HEATER SHOULD SLOPE DOWNWARDS TOWARDS THE RETURN BEND AND ON LINEAR VARIANTS SHOULD SLOPE DOWNWARDS TOWARDS BURNER BY APPROX. ½” FOR HORIZONTAL INSTALLATIONS AS SHOWN BELOW (DIAGRAMS EXAGGERATED FO R CLARITY)
1/2”
1/2”
Outlet
U Tube heater side view
U bend
Linear heater side view
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 B B1 C1 C2 C3 D1 D2 E
Clearance to Combustibles, inches (cm)
60
74 (188) 29 (74) 41 (105) 20 (51) / 10* (26)* 8 (21) 22 (56) 8 (21) 12 (31) 12 (31)
80
100
125
150
170
200
* distance with end caps fitted.
74 (188) 29 (74) 41 (105) 20 (51) / 10* (26)* 8 (21) 22 (56) 8 (21) 12 (31) 12 (31)
74 (188) 32 (82) 41 (105) 20 (51) / 10* (26)* 8 (21) 22 (56) 8 (21) 16 (41) 12 (31)
74 (188) 39 (99) 47 (120) 20 (51) / 10* (26)* 8 (21) 22 (56) 20 (51) 18 (46) 12 (31)
74 (188) 39 (99) 48 (122) 20 (51) / 10* (26)* 8 (21) 22 (56) 20 (51) 18 (46) 12 (31)
86 (219) 48 (122) 48 (122) 20 (51) / 10* (26)* 11 (28) 22 (56) 20 (51) 20 (51) 12 (31)
86 (219) 48 (122) 48 (122) 20 (51) / 10* (26)* 11 (28) 22 (56) 20 (51) 20 (51) 12 (31)
WARNING:
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be 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.
4
Figure 2 Clearance to Combustibles.
The minimum clearances to combustible materials are given in the tables below. 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.
D2
WARNING!
provision in the building for
Ensure that there is adequate
Angled view.
combustion and ventilation air supply.
Installation must meet minimum
applicable
requirements and appliciable codes.
A
.
0° to 55°
Outlet end.
D1
End
B1
Side
unvented
Above outlet
C3
unvented
Return end on
U tube heater
B
Below
A
B
Side
vented
End view.
heater
unvented
Above
Reflector
C2
Burner end.
C1
Above
Burner
5
E
Service
distance
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 ” 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 minimum pipe bend diameter (minimum 10” - 250mm, maximum 14” - 350mm) & pipe expansion distance (minimum 1” - 28mm, maximum 3¾”) - 95mm.
The correct installation as shown will allow
for approx 4” of movement due to expansion.
Figure 3. Correct orientation of Ball Valve
Gas Flow
Gas Flow
Figure 4. Correct Installation of Flexible Gas Connection
WARNING: FIRE OR EXPLOSION HAZARD - 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. It is therefore essential to provide some flexibility in the final gas line connection by use of an approved flexible connector as shown in the drawings.
6
* 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 above 150,000Btu/h, ¾” ID x 36” long NOTE: For Canada all heaters MUST use a hose 36” long See Table 3
CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. FOR HEATERS
Table 3
HOSE SIZE USA CANADA
3/4” CE4
CONTACT FACTORY
UPTO 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
Required Gas Pressure (in W.C) (60,000 TO 150,000 BTU)
Required Gas Pressure (in W.C) (170,000 TO 200,000 BTU)
Max Supply Pressure (in W.C)
Gas Supply
1.5 Electrical Connections
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.
This appliance must be electrically grounded
Supply 120V 60Hz single phase. Standard heater 0.16HP. Current rating 1.2 amp max (inductive). Fuse: external 3 amp.
Important: All electrical work should be done by a qualified electrician in strict accordance with the National Electrical Code ANSI/NFPA 70 or Canadian Codes CSA C22.1.
5.0 11.0
7.0 11.0
14.0 14.0
Connection ½” N.P.T thread
The electrical supply to the heater is by three wires: live, neutral and ground connections. Install in accordance with all state & local codes.
Where alternative manufacturers controls are used, please refer to their instructions for their installation details.
7
Figure 5a. Single and Multiple Heater Installations 120V Control
KEY:
T
T
110V Thermostat
120V Thermostat
BK
W
W
G
BK
Burner 1
GND L2 L1 (HOT)
120V 60Hz 1 Ph Supply circuit
G-GREEN W-WHITE BK-BLACK
Other burners
BK
G
Figure 5b. Single Heater Installations 24V Control
BK
L1
Gas Control
IND
MV
PS1
PS0
W1
R
X
C
COM
R
R
Y
Y
K
K
BR
GR
BL
METHOD:­Cut and strip pink cables linking terminals W1 and R Attach thermostat wires using suitable wire nuts.
X
24V Thermostat
C
T
T
other burners
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
RW1
K - PINK
R - RED
Y - YELLOW
Figure 5c. Multiple Heater Installations 24V Control
C
T
T
R
RW1
BK
S-0700
R
G
24V Thermostat
Fan center relay
(Suppled by others)
KEY: G - GREEN W - WHITE BK - BLACK R - RED
8
40VA
30
Trans
Relay
BK
W
C
L2
L1
G
BK
GND L2 L1 (HOT)
120V 60Hz 1 Ph Supply circuit
Other burners
Burner 1
W
other burners
Figure 6. Internal Burner Wiring Diagram.
120V AC Fan
G
R
W
BL
G
E
LN
120V/60Hz AC
Supply
KEY:
BK
G
W
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
G
BK
W
R - RED
W - WHITE
Y - YELLOW
YY
Pressure Switch
120v/24VAC 60Hz
Transformer
BR
Power ON (red)
BL BR
Burner ON (amber)
BK
Y
IND
R
MV
R
L1
K
PS1
PS0
K
W1
R
Gas Control
BR
BL
GR
X
C
COM
R
GR
G
M
C
E
Y
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
RGR
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
9
1.6 Vent Requirements and Details
1.6.1 Unvented units
Heaters may be installed without a vent 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 gasses 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. The maximum
recommended vent length is 25ft (7.6m) with a maximum of two elbows. All connections
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.
Maximum length of vent is 25ft (7.6m) with two
- 90° elbows.
This protects the building material from degradation by the vent gasses.
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) away from any air intake to the building.
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.
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.
A fresh air duct of 4”(101mm) dia. 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 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.
Runs of 12ft (3.6m) or shorter can use 4” (101mm) dia vent. Runs over 12ft (3.6m) should use 6” (152mm) vent pipe.
Any portion of vent that passes through a combustible wall must be insulated, or use an approved insulating thimble.
Standard vent terminals must extend at least 6” (152mm) from the wall and at least 24” (609mm) from any combustible overhang.
10
Figure 7.a Vertical Venting.
CODE APPROVED VENT THROUGH ROOF
Figure 7.b Horizontal Venting.
SUPPLIED BY OTHERS
4" (101mm) TO 6" (152mm) DIA. ALUMINUM ADAP TER
REQUIRED ONLY FOR 6" (152mm) DIA. VENTS
APPROVED CAT III VENT PIPE
ALUMINUM 4" (101mm) O.D. OR 6" (152mm) O.D. FLUE
SEAL JOINTS WITH
HIGH TEMPERATURE SILICONE
END OF RADIANT TUBE
REFLECTOR
ENSURE ALL JOINTS ARE
HIGH TEMPERATURE
APPROVED CAT 3 VENT PIPE
ROOF
SEAL JOINTS WITH
SEALED
SILICONE
SEAL
12'-0" (3.66m)
12'-0" (3.66m)
(APPROXIMATE
MAXIMUM DIMENSIONS)
4" (101mm) TO 6" (152mm) DIA. ALUMINUM ADAPTER
REQUIRED ONLY FOR 6" (152mm) DIA. VENT
VENT CAT III ELBOW
VENT ADAPTOR ELBOW
6" (152mm)
CAT III ADAPTER
COLLAR
TERMINAL
SUPPLIED BY OTHERS
COUPLER
END OF
REFLECTOR
RADIANT TUBE
ALUMINUM 4" (101mm) O.D. MAX IMUM LENGTH = 12'-0" (3.66m) ALUMINUM 6" (152mm ) O.D.MAX IMUM LENGTH = 25'-0" (7.62m) (PLUS A MAXIMUM OF 2 x 90° BENDS
ELBOWS
Figure 7.c Fresh Air Ducted Intake.
ALUMI NUM 4" (101 mm) O.D. PIPE
MAX LENGTH = 2 5'- 0" ( 7.62 m) WIT H 2-90° LONG RADIUS BENDS
CLAMPS
WITH TWO– 90° ELBOW S
4.25” (108mm) O.D FLEXIBLE DUCT
4" ( 106mm) O.D. FLEXI BLE DUCT
WALL
TERMINAL
36" (914mm) MIN CENTERS
INLET WITH BIRD SCREEN
36" (914mm) MIN CENTERS
Figure 7.d Wall Terminal Intake Kit.
INLET WITH BIRD SCREEN
WALL
SEAL JOINTS WITH
SILICONE OR DUCT TAPE
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
BURNER
6" (152mm)
11
1.8 Technical Details - Table 5
No of Injectors
Gas Connection
Electrical Supply
Vent size (in)
Unitary Fan Motor Details
Current Rating
Natural Gas LP Gas
MODEL
BTU/Hr BTU/Hr
60
80 100 125 150 170
60,000 60,000 20 (6.1) 40 (12.1) 20 (6.1) 40 (12.1)
80,000 80,000 20 (6.1) 40 (12.1) 20 (6.1) 40 (12.1)
100,000 100,000 30 (9.1) 50 (15.2) 40 (12.1) 40 (12.1)
123,500 125,000 40 (12.1) 60 (18.3) 40 (12.1) 60 (18.3)
150,000 150,000 40 (12.1) 70 (21.3) 40 (12.1) 60 (18.3)
169,000 169,000 50 (15.2) 80 (24.4) 60 (18.3) 80 (24.4)
200 200,000
Ignition
N/A
1
½” N.P.T
120 volt 1 phase 60Hz
4” or 6” (101mm or 152mm)
120 volt 1 phase 60Hz
1.2A MAX
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)
50 (15.2) 80 (24.4) 60 (18.3) 80 (24.4)
Appliances can be installed up to 10,000 ft in the USA. Altitude conversion kits are available on request.
USA Natural Gas 0- 2000 ft (0-610m)
Size “WC
60 80 100 125 150 170 200
4.2 3.5 3.5 4.1 4.2 3.4 3.5
USA Natural Gas 2001- 4000 ft (611-1220m)
Size “WC
60 80 100 125 150 170 200
4.0 3.3 3.3 3.9 4.0 3.2 3.3
CANADA Natural Gas 0- 2000 ft (0-610m)
Size “WC
60 80 100 125 150 170 200
4.2 3.5 3.5 4.1 4.2 3.4 3.5
USA LP Gas 0- 2000 ft (0-610m)
Size “WC
60 80 100 125 150 170 200
6.0 5.2 8.2 6.6 7.0 5.7 N/A
USA LP Gas 2001- 4000 ft (611-1220m)
Size “WC
60 80 100 125 150 170 200
5.8 5.0 8.0 6.4 6.8 N/A
CANADA LP Gas 0- 2000 ft (0-610m)
Size “WC
60 80 100 125 150 170 200
6.0 5.2 8.2 6.6 7.0 5.7 N/A
CANADA Natural Gas 2001- 4500 ft (611-1370m)
Size “WC
60 80 100 125 150 170 200
4.0 3.3 3.3 3.9 4.0 3.2 3.3
12
CANADA LP Gas 2001- 4500 ft (611-1370m)
Size “WC
60 80 100 125 150 170 200
N/A
5.8 5.0 8.0 6.4 6.8 N/A
Technical Details continued
USA & CANADA Natural Gas 0- 2000 ft (0-610m)
Size
Burner Orifice Plate
Part No.
Fan Type
Fan Orifice
Part No.
Injector
Part No.
Pressure Switch
Part No.
60 80 100 125 150 170 200
269954 269955 269943 269944 269945 269946 269946
270476
269923 269922 269923 269927 269926 266930 269938
270400 270402 270404 270406 270408 270409 270410
270386 270387
USA & CANADA LP Gas 0- 2000 ft (0-610m)
Size
Burner Orifice Plate
Part No.
Fan Type
Fan Orifice
Part No.
Injector
Part No.
Pressure Switch
Part No.
60 80 100 125 150 170 200
269948 269949 269950 269951 269952 269953
270476 270475
269925 269925 269928 266931 269933 269937
270398 270399 270399 270400 270401 270403
270386
270475
N/A
13
Technical Details continued
U Tube Straight Tube
MODEL
U20 U40 U60 U80 S20 S30 S40 S50 S60 S70 S80
60
80 100 125 150 170
200
MODEL
60
80 100 125 150 170
Tube Type Material
Calcoat™ Mild Steel
TUBE 1 REMAINDER 10 (3.0)
TUBE 1 REMAINDER 10 (3.0)
TUBE 1 REMAINDER 15 (4.6)
TUBE 1 REMAINDER 20 (6.1)
TUBE 1 REMAINDER 20 (6.1)
TUBE 1 & 2 REMAINDER 25 (7.6)
Min. Distance to
Bend ft (m)
200
TUBE 1 & 2 REMAINDER 25 (7.6)
Options * Not available on LP Gas
1 All standard units fitted with unvented vent, natural gas and aluminized steel reflectors. 2 1 off 180° bend (U) or upto 2 off 90° bends (L) can be fitted at no less than 50% of the total heater length.
3 4” (101mm) or 6” (152mm) vent terminal.
4 Combustion air kit. 5 Reflector end caps. 6 Altitude conversion kit. 7 Propane and propane altitude conversion kit.
14
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