Model VPS
Burner/Control Box
with 20 - 80 ft Tube/Reflector Length
Doc No 700101 (06-15), Page
Part No. 270683
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
Document Index.
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.
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 Turbulator Strips and Burner Inserts
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 Troubleshooting Guide
6 Replacing Parts
6.1 Burner Controller Replacement
6.2 Air Pressure Switch Replacement
6.3 Gas Valve Replacement
6.4 Optional Extra Kits
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
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.
Doc No 700101 (06-15), Page 2
C. The installation must conform with local
D. The unit shall be electrically grounded in
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.
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 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.
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.
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.
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
NOTE.
'S' HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
SUITABLE CHAIN
WORKING LOAD
LIMIT 100LB
EXHAUST
END
CHAIN
Doc No 700101 (06-15), Page 3
55° SUSPENSION
BURNER
END
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
1/2”
”
VENTED
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.
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.
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(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 700101 (06-15), Page 4
Figure 2 Clearance to Combustibles.
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.
D2
A2
.
0° to 55°
Angled view.
Return end on
U tube heater
A1
WARNING!
combustion and ventilation air supply.
provision in the building for
Ensure that there is adequate
Installation must meet minimum
B
requirements and applicable codes.
Below
Outlet end.
heater
D1
End
B1
Side
C3
unvented
unvented
unvented
Above outlet
Above
Reflector
C2
Burner end.
B
Side
Doc No 700101 (06-15), Page 5
vented
A
End view.
C1
Above
Burner
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
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 minimum
pipe bend diameter (minimum 10” - 250mm,
maximum 14” - 350mm) & pipe expansion
distance (minimum 1⅛” - 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 - 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 700101 (06-15), Page 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 UP
Table 3
HOSE SIZE USA CANADA
3/4” CE4
CONTACT
FACTORY
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
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)
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 (inductive):
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.
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
installation details.
5.0 11.0
7.0 11.0
14.0 14.0
Connection ½” N.P.T thread
Doc No 700101 (06-15), Page 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
R
C
RW1
T
T
24V Thermostat
BK
S-0700
W
40VA
30
Trans
Relay
C
L2
L1
R
G
G
BK
Burner 1
Fan center relay
(Suppled by others)
KEY:
G - GREEN
BK
W
W - WHITE
BK - BLACK
R - RED
Doc No 700101 (06-15), Page 8
GND
L2
L1 (HOT)
120V 60Hz 1 Ph
Supply circuit
Other burners
other burners
Figure 6. Internal Burner Wiring Diagram.
120V/60Hz AC Supply
G
LN
120V AC Fan
KEY:
BL - BLUE
G
BK
G
R
W
W
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
BL
G
BK
W
R - RED
W - WHITE
Y - YELLOW
BK
L1
YY
Pressure Switch
120v/24VAC 60Hz
Transformer
BR
Power ON (red)
BLBR
Optional
24V
Thermostat
RGR
Burner ON (amber)
Y
Y
R
R
IND
MV
K
PS1
PS0
K
W1
R
Gas Control
BR
BL
GR
X
C
COM
R
GR
G
M
C
E
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.
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.
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 700101 (06-15), Page 9
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 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.
Runs of 12ft (3.6m) or shorter can use
4” (101mm) dia. vent. Runs over 12ft (3.6m)
should 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 and/or vent pipe manufacturer.
Standard vent terminals must extend at least
6” (152mm) from the wall and at least
24” (609mm) from any combustible overhang.
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) 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) 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 (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 700101 (06-15), Page 10
Figure 7.a Vertical Venting.
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 700101 (06-15), Page 11
1.8 Technical Details
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
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
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 Tubes
Each heating unit has two types of emitter tube.
For details of the tube types and position
please refer to the table (page 13 of this
instruction manual).
Identify and position tubes on saw horses. For
aesthetics it is advisable to position all tube 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.
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 tube exactly as
indicated in the assembly drawings.
Locate turbulator strip sections. Install the first
turbulator strip into the open end of the last tube
(only after it has been suspended and
connected to the previous tube.)
Interlock the next section of turbulator strip as
shown in the diagram below.
Doc No 700101 (06-15), Page 14
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