Reznor VPS150 Installation Manual

Download

Page 1

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

Doc No 700101 (06-15), Page

Part No. 270683

Page 2

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.

Page 3

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

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

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.

Table 1

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

Clearance to Combustibles, inches (cm)

100

125

150

170

(188)

(219)

15° = 72 (183) 25° = 68 (173) 35° = 61 (155) 45° = 53 (135) 55° = 43 (110)

15° = 82 (209) 25° = 78 (199)

(74)

(82)

(99)

(122)

(105)

(120)

(122)

20 (51) /

10* (26)*

20 (51) /

10* (26)*

20 (51) /

10* (26)*

20 (51) /

10* (26)*

20 (51) /

10* (26)*

20 (51) /

10* (26)*

(21)

(28)

(56)

(21)

(51)

(31)

(41)

(46)

(51)

(31)

35° = 71 (181)

200

* distance with end caps fitted.

(219)

WARNING:

45° = 61 (155) 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 700101 (06-15), Page 4

Page 5

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.

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

Doc No 700101 (06-15), Page 5

vented

End view.

Above

Burner

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 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

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

Page 7

* 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):

1.8 amp max (models 60 - 150)

1.0 amp max (models 170 & 200) 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.

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

Page 8

Figure 5a. Single and Multiple Heater Installations 120V Control

KEY:

110V Thermostat

120V Thermostat

Burner 1

GND L2 L1 (HOT)

120V 60Hz 1 Ph Supply circuit

G-GREEN W-WHITE BK-BLACK

Other burners

Figure 5b. Single Heater Installations 24V Control

Gas Control

IND

PS1

PS0

COM

METHOD:Cut and strip pink cables linking terminals W1 and R Attach thermostat wires using suitable wire nuts.

24V Thermostat

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

RW1

24V Thermostat

S-0700

40VA

Trans

Relay

Burner 1

Fan center relay

(Suppled by others)

KEY: G - GREEN

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

Page 9

Figure 6. Internal Burner Wiring Diagram.

120V/60Hz AC Supply

120V AC Fan

KEY:

BL - BLUE

BK - BLACK

BR - BROWN

GR - GREY

G - GREEN

K - PINK

R - RED

W - WHITE

Y - YELLOW

Pressure Switch

120v/24VAC 60Hz

Transformer

Power ON (red)

BL BR

Optional

24V

Thermostat

RGR

Burner ON (amber)

IND

PS1

PS0

Gas Control

COM

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.

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 700101 (06-15), Page 9

Page 10

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

Page 11

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

Page 12

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

60,000 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

200,000

N/A

50 80 60 80

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

USA 0- 2000 ft (0-610m) 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)

Size

Burner Orifice Plate Part No.

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)

Size

Burner Orifice Plate Part No.

Flame Plate Part No.

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) 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

60 80 100 125 150 170 200

N/A

270475

270375 270376

270389 270390

60 80 100 125 150 170 200

269959

270476 270475

N/A

270375 270389

Doc No 700101 (06-15), Page 12

Page 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*

* Nat Gas ONLY

MODEL

80 100 125 150 170 200

● ● ●

● ● ● ●

● ● ● ● ● ●

Tube Type Material

Calcoat™ Mild Steel

Min. Distance to

Bend ft (m)

TUBE 1 REMAINDER 10 (3.0)

TUBE 1 REMAINDER 15 (4.6)

TUBE 1 REMAINDER 20 (6.1)

TUBE 1 & 2 REMAINDER 25 (7.6)

Doc No 700101 (06-15), Page 13

Page 14

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 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

Page 15

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 tube(s). Add further strips to form the correct length required.

For specific configurations see detailed assembly diagrams on pages 20 to 30.

Fit three turbulator strips here

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.

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.

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

Fit the remaining turbulator strips here

Doc No 700101 (06-15), Page 15

Page 16

2.2.2.2 Burner Inserts

The burner insert (when required) is inserted into the first heat exchanger tube from where it is joined to the second 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 #270126 & tube straps part #270572.

ONLY used as the first suspension bracket positioned CLOSEST TO THE BURNER.

SUSPENSION BRACKET

RADIANT

TUBE

PART #270126

2.2.3.2 Reflector Support Brackets

Reflectors are positioned above the emitter tube with a reflector support bracket part #270569.

RADIANT TUBE

TUBE

STRAP

SUPPLIED

NUT &

BOLT

SUPPLIED NUT & BOLT

RADIANT

TUBE

"A"

VIEW ON "A"

PARTS #270126 plus #270572

TUBE

STRAP

Slip the suspension first bracket assembly part #270126 onto the first section of tube in the position as indicated on the assembly drawing.

Locate the tube strap assembly part #270572 and loosen the nut and bolt.

Position the strap over the 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 #270126 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 #270126 onto the tube(s) in their relevant positions as shown on the assembly drawing.

REFLECTOR BRACKET #270569

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 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 coupling onto the end of the existing emitter tube. Slide the end of the next tube into the other side of the coupling.

Doc No 700101 (06-15), Page 16

Page 17

With both tube ends pushed fully into the coupling and the bolts towards the bottom, using a 9/16” wrench, tighten the coupling bolts moving between each bolt in sequence to ensure equal pressure is applied to each bolt.

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 final 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 #270569.

Each reflector must OVERLAP the

previous one as indicated by their individual assembly sheets.

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 #270569.

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 #270126

and fixing #270572

Doc No 700101 (06-15), Page 17

Support Bracket

part #270569

non-slip overlap

Support Bracket

part #270569

slip overlap

Support Bracket

part #270569

non-slip overlap

Subsequent support brackets to

be alternating 'slip' and 'non-slip'

Page 18

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.

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 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 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

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

16” crs

U Bend

Doc No 700101 (06-15), Page 18

End Caps

15”

Page 19

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 700101 (06-15), Page 19

Page 20

Figure 9. Heater Assembly: Model Linear 60-S20.

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

6"-9" REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

TURBULATOR(S)

(SEE DETAIL)

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

PART #205546

QTY 1 REQUIRED

STANDARD 4" COUPLER

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #116019

QTY 3 REQUIRED

TURBULATOR SECTION

21'6½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

PART #270126

SUSPENSION BRACKET

DISTANCE BETWEEN

SUSPENSION POINTS

PART #270126 PLUS

STRAP PART #270572

NO TO EXCEED 12'

10' 3" REFLECTORS TYPICAL OF 2

END CAPS

(OPTIONAL)

BURNER

COUPLER

(SEE DETAIL)

BURNER INSERT

ASSEMBLY OVERVIEW

DETAILS

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

PART #270126 plus STRAP #270572

FIRST SUSPENSION POINT BRACKET

QTY 2 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270489 (5FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED NAT GAS ONLY

PART #270569

QTY 2 REQUIRED

REFLECTOR SUPPORT BRACKET

Doc No 700101 (06-15), Page 20

Page 21

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

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

6" REFLECTOR OVERLAP

PART #270126

SUSPENSION BRACKET

6" REFLECTOR OVERLAP

TURBULATOR

COUPLER

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

PART #205546

QTY 2 REQUIRED

STANDARD 4" COUPLER

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

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

PART #270126

SUSPENSION BRACKET

NO TO EXCEED 12'

DISTANCE BETWEEN

SUSPENSION POINTS

10' 3" REFLECTORS TYPICAL OF 3

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

BURNER

COUPLER

(SEE DETAIL)

BURNER INSERT

ASSEMBLY OVERVIEW

DETAILS

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

QTY 3 REQUIRED

BRACKET PART #270126

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

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 #270569

QTY 3 REQUIRED

REFLECTOR SUPPORT BRACKET

Doc No 700101 (06-15), Page 21

Page 22

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

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

PART #270126

41'6½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

TURBULATOR

COUPLERCOUPLERCOUPLER

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

(SEE DETAIL)

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

PART #205546

QTY 3 REQUIRED

STANDARD 4" COUPLER

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 125/150 ONLY

6" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

TYPICAL OF 4

10' 3" REFLECTORS

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700101 (06-15), Page 22

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

QTY 4 REQUIRED

BRACKET PART #270126

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

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 #270569

QTY 4 REQUIRED

REFLECTOR SUPPORT BRACKET

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

BURNER INSERT

BURNER

ASSEMBLY OVERVIEW

DETAILS

Page 23

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

END CAPS

(OPTIONAL)

2" MINIMUM

SUSPENSION BRACKET

PART #270126

3" REFLECTOR

OVERLAP

PART #270126

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

NOTE: The 200 S50 model

requires a different fan orifice

plate. See P15 for details.

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

DETAIL

REFLECTOR SUPPORT BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

51'6½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

PART #270126

SUSPENSION BRACKET

COUPLER COUPLER COUPLER COUPLER

PART #205546

QTY 4 REQUIRED

STANDARD 4" COUPLER

QTY 5 REQUIRED

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 200 NG ONLY

QTY 2 REQUIRED SIZE 170 LPG ONLY

PART #270489 (5FT)

PART #1005500 (3FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 100 NG ONLY

QTY 1 REQUIRED SIZE 125 NG ONLY

TYPICAL OF 5

10' 3" REFLECTORS

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700101 (06-15), Page 23

BURNER

(SEE DETAIL)

BURNER INSERT

PART #270569

QTY 5 REQUIRED

ASSEMBLY OVERVIEW

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

FIRST SUSPENSION POINT BRACKET

DETAILS

REFLECTOR SUPPORT BRACKET

Page 24

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

END CAPS

(OPTIONAL)

SUSPENSION BRACKET

PART #270126

3" REFLECTOR

OVERLAP

PART #270126

3" REFLECTOR

OVERLAP

PART #270126

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

PART #205546

QTY 5 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

STANDARD 4" COUPLER

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

PART #270126

61'6½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

SUSPENSION BRACKET

PART #270126

PART #270126 PLUS

STRAP PART #270572

6" REFLECTOR

OVERLAP

10' 3" REFL'S

END CAPS

(OPTIONAL)

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

QTY 6 REQUIRED

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

REFLECTOR SUPPORT

BRACKET PART #270569

BURNER INSERT

NON-SLIP REFLECTOR OVERLAP

(SEE DETAIL)

COUPLER COUPLER COUPLER COUPLER COUPLER

TYPICAL OF 6

PART #1005500 (3FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 125 NG ONLY

PART #270569

QTY 6 REQUIRED

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

FIRST SUSPENSION POINT BRACKET

ASSEMBLY OVERVIEW

BURNER

DETAILS

REFLECTOR SUPPORT BRACKET

Doc No 700101 (06-15), Page 24

Page 25

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

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

PART #205546

QTY 6 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

STANDARD 4" COUPLER

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

71'6½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

QTY 7 REQUIRED

BRACKET PART #270126

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

PART #270126

SUSPENSION BRACKET

TYPICAL OF 7

10' 3" REFL'S

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

COUPLER COUPLER COUPLER COUPLER COUPLER COUPLER

BURNER

NON-SLIP REFLECTOR OVERLAP

ASSEMBLY OVERVIEW

DETAILS

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

PART #270126 plus STRAP #270572

QTY 1 REQUIRED OF EACH

PART #270569

QTY 7 REQUIRED

REFLECTOR SUPPORT BRACKET

Doc No 700101 (06-15), Page 25

Page 26

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

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVER LAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

PART #205546

QTY 7 REQUIRED

STANDARD 4" COUPLER

PART #270126

SUSPENSION BRACKET

3" REFLECTOR

OVERLAP

81'6½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270126

SUSPENSION BRACKET

COUPLER COUPLER COUPLER COUPLER COUPLER

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

QTY 8 REQUIRED

6" REFLECTOR

OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

COUPLER

BURNER

REFLECTOR SUPPORT

BRACKET PART #2 70569

NON-SLIP REFLECTOR OVERLAP

ASSEMBLY OVERVIEW

DETAILS

PART #270126

SUSPENSION BRACKET

6" REFLECTOR

OVERLAP

PART #270126

SUSPENSION BRACKET

TYPICAL OF 8

10' 3" REFL'S

DISTANCE BETWEEN SUSPENSION POINTS NO TO EXCEED 12'

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

TUBE & REFLECTOR SUSPENSION

FIRST SUSPENSION POINT BRACKET

BRACKET PART #270126

PART #270126 plus STRAP #270572

QTY 1 REQUIRED OF EACH

PART #270569

QTY 8 REQUIRED

REFLECTOR SUPPORT BRACKET

Doc No 700101 (06-15), Page 26

Page 27

Figure 16. Heater Assembly: Model U tube 60-U20 and 80-U20.

2" MINIMUM

12'1½" NOMINAL OVERALL ASSEMBLED LENGTH

3' 3"

DETAIL

REFLECTOR SUPPORT BRACKET

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

PART #270126

COUPLERS

SUSPENSION BRACKET

BURNER INSERT

DISTANCE BETWEEN

TURBULATOR

(SEE DETAIL)

10' 3" REFLECTORS TYPICAL OF 2

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

PART #270126

SUSPENSION BRACKET

(SEE DETAIL)

PART #205546

QTY 2 REQUIRED

STANDARD 4" COUPLER

SUSPENSION POINTS

NO TO EXCEED 12'

TURBULATOR SECTION

PART #116019

QTY 1 REQUIRED SIZE 60 ONLY

QTY 3 REQUIRED SIZE 80 ONLY

PART #270126

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700101 (06-15), Page 27

BURNER

TUBE & REFLECTOR SUSPENSION

QTY 3 REQUIRED

BRACKET PART #270126

BURNER INSERT DETAIL

PART #270489 (5FT)

PART #270569

QTY 1 REQUIRED NAT GAS ONLY

QTY 2 REQUIRED

PART #270126 PLUS

STRAP PART #270572

SUSPENSION BRACKET

QTY 1 REQUIRED OF EACH

REFLECTOR SUPPORT BRACKET

ASSEMBLY OVERVIEW

PART #270126 plus STRAP #270572

FIRST SUSPENSION POINT BRACKET

DETAILS

Page 28

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

3' 3"

REFLECTOR SUPPORT

SLIP REFLECTOR OVERLAP

BRACKET PART #270569

SUSPENSION BRACKET

BRACKET PART #270569

REFLECTOR SUPPORT

PART #270126

COUPLERS

NON-SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

PART #270126

BRACKET PART #270569

SLIP REFLECTOR OVERLAP

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

SUSPENSION BRACKET

SUSPENSION POINTS

DISTANCE BETWEEN

NO TO EXCEED 12'

6"-9" REFLECTOR OVERLAPS

COUPLERS

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

PART #205546

QTY 4 REQUIRED

STANDARD 4" COUPLER

PART #116019

TURBULATOR SECTION

QTY 4 REQUIRED SIZE 150 ONLY

22'1½" NOMINAL OVERALL ASSEMBLED LENGTH

SUSPENSION BRACKET

PART #270126

SUSPENSION BRACKET

PART #270126

TURBULATOR

(SEE DETAIL)

END CAPS

(OPTIONAL)

PART #270126

SUSPENSION BRACKET

(SEE DETAIL)

BURNER INSERT

10' 3" REFLECTORS TYPICAL OF 4

SUSPENSION BRACKET

STRAP PART #270572

PART #270126 PLUS

QTY 5 REQUIRED

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

PART #270489 (5FT)

PART #1005500 (3FT)

BURNER INSERT DETAIL

QTY 1 REQUIRED SIZE 125 NG ONLY

QTY 1 REQUIRED SIZE 60-100 NG ONLY

BURNER

PART #270569

QTY 4 REQUIRED

QTY 1 REQUIRED OF EACH

REFLECTOR SUPPORT BRACKET

ASSEMBLY OVERVIEW

PART #270126 plus STRAP #270572

FIRST SUSPENSION POINT BRACKET

DETAILS

Doc No 700101 (06-15), Page 28

Page 29

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

3' 3"

2" MINIMUM

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

DETAIL

COUPLERS

REFLECTOR SUPPORT

PART #270126

SUSPENSION BRACKET

SLIP REFLECTOR OVERLAP

BRACKET PART #270569

PART #270126

SUSPENSION BRACKET

REFLECTOR SUPPORT BRACKET

PART #205546

QTY 6 REQUIRED

STANDARD 4" COUPLER

REFLECTOR SUPPORT

PART #270126

SUSPENSION BRACKET

SLIP REFLECTOR OVERLAP

BRACKET PART #270569

PART #270126

SUSPENSION BRACKET

COUPLERS

6" REFLECTOR OVERLAPS

6"-9" REFLECTOR OVERLAPS

32'1½" NOMINAL OVERALL ASSEMBLED LENGTH

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

PART #270126

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION

POINTS NO TO EXCEED 12'

PART #270126

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

Doc No 700101 (06-15), Page 29

10' 3" REFLECTORS TYPICAL OF 6

BURNER

QTY 7 REQUIRED

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

PART #270126

SUSPENSION BRACKET

(SEE DETAIL)

BURNER INSERT

SUSPENSION BRACKET

STRAP PART #270572

PART #270126 PLUS

FIRST SUSPENSION POINT BRACKET

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

BURNER INSERT DETAIL

REFLECTOR SUPPORT BRACKET

PART #1005500 (3FT)

QTY 1 REQUIRED SIZE 125 NG ONLY

PART #270569

QTY 6 REQUIRED

ASSEMBLY

OVERVIEW

DETAILS

Page 30

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

3' 3"

SUSPENSION BRACKET

PART #270126

REFLECTOR SUPPORT

BRACKET PART #270569

REFLECTOR SUPPORT

BRACKET PART #270569

REFLECTOR SUPPORT

SLIP REFLECTOR OVERLAP

COUPLERS

NON-SLIP REFLECTOR OVERLAP

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

COUPLERS COUPLERS

SUSPENSION BRACKET

PART #270126

SLIP REFLECTOR OVERLAP

REFLECTOR SUPPORT

BRACKET PART #270569

REFLECTOR SUPPORT

NON-SLIP REFLECTOR OVERLAP

PART #205546

QTY 8 REQUIRED

2" MINIMUM

DETAIL

REFLECTOR SUPPORT BRACKET

STANDARD 4" COUPLER

SLIP REFLECTOR OVERLAP

BRACKET PART #270569

REFLECTOR SUPPORT

SLIP REFLECTOR OVERLAP

42'1½" NOMINAL OVERALL ASSEMBLED LENGTH

PART #270126

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

COUPLERS

PART #270126

SUSPENSION BRACKET

REFLECTOR SUPPORT

BRACKET PART #270569

NON-SLIP REFLECTOR OVERLAP

QTY 9 REQUIRED

BRACKET PART #270126

TUBE & REFLECTOR SUSPENSION

PART #270126

SUSPENSION BRACKET

DISTANCE BETWEEN SUSPENSION

POINTS NO TO EXCEED 12'

10' 3" REFLECTORS TYPICAL OF 8

PART #270126

SUSPENSION BRACKET

END CAPS

(OPTIONAL)

BURNER

PART #270126

SUSPENSION BRACKET

PART #270569

QTY 8 REQUIRED

FIRST SUSPENSION POINT BRACKET

QTY 1 REQUIRED OF EACH

PART #270126 plus STRAP #270572

REFLECTOR SUPPORT BRACKET

SUSPENSION BRACKET

STRAP PART #270572

PART #270126 PLUS

ASSEMBLY

OVERVIEW

DETAILS

Doc No 700101 (06-15), Page 30

Page 31

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 leaks in accordance with local and National Safety codes.

Open shut off gas valve and test gas connections for leaks 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 clock 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 vent 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 energize at the same time 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, after approximately 15 seconds the gas valve will close and the spark ignition will de-energize.

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 run for 120 seconds and then stop.

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 or digital manometer to the pressure test point provided on the combination gas control valve.

Remove the cover from the pressure regulator to reveal the adjusting 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 12)

Manometer

Multimeter

Doc No 700101 (06-15), Page 31

Page 32

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 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 then ‘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. The burner should shut off within 4 seconds .

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

Close the controls door and secure with the screw.

Doc No 700101 (06-15), Page 32

Page 33

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 for leaks.

Switch on electrical supply.

The red lamp 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 the building owner.

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 700101 (06-15), Page 33

Page 34

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.

Soft Brush

269958 80/100 LP

269957 60 LP

Part Number

A Ignition Controller 204955

B Gas Valve 270378 (NG) 270496 (LP)

C Power On Red LED 270474

D Burner On Amber LED 270473

F Burner Tube 270424

G Burner head 270425

H Injector See section 1.8 P12

Note: Cables Omitted

Part Number

I Igniter Assembly 270441

J Injector Carrier

K Combustion Fan

L Pressure Switch

M Gaskets

N Transformer

P Burner Orifice Plate

Q Flame Plate (not shown)

For Clarity

See section 1.8 P12

2 off 270366

175265

See section 1.8 P12

See photos above

Doc No 700101 (06-15), Page 34

Page 35

4.3 Burner Removal Step 1: Isolate power and gas supplies.

Step 2: Unplug the power connectors.

Step 3: Detach the gas supply as shown

below, taking care to support the burner connection.

Step 5: Loosen the set screw on the burner

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

Step 6: Remove the burner and position

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

4.4 Burner Gas Injector Servicing Step 1.a: Remove the burner support casting

and gasket.

Step 4: If fresh air is connected, slacken

hose clip and remove the flexible hose from the burner.

Doc No 700101 (06-15), Page 35

Step 1.b: The burner head assembly can be

disconnected by separating the connectors of the ignition lead, ground lead assembly and

removing the pressure switch silicon tube.

Page 36

Step 2: The gas injector can be inspected and

replaced if contaminated or blocked.

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

Step 3: Reconnect ignition leads, ground lead

and silicone tube to test nipple. Refit gasket and support casting.

4.5 Burner Head and Electrode Servicing

Step 1: Check the pepper pot burner head for

contamination. If necessary this can be removed, see picture below. It can be cleaned together with the Inside of the burner head.

Step 3: The condition of the igniter assembly

can be checked for deterioration. However, we advise replacement at each service to ensure continued reliability. Detach the electrode assembly from the burner head by removing the two screws and separating the igniter lead connectors.

Step 4: Refit the electrode assembly and

ensure the connections are secure to prevent incorrect sparking .

Step 5: Check the positions and spark gap as

shown below.

Step 6: The burner assembly is ready to refit

after servicing the combustion fan and the radiant tube assembly.

4.6 Combustion Fan Assembly Step 1: If ducted air is fitted, loosen hose clamp

and remove the flexible hose from the fan.

Step 2: The pepper pot burner head can be

replaced ensuring the 5 outer holes are aligned alongside the probes. (See diagram below).

Holes positioned adjacent to probes

Doc No 700101 (06-15), Page 36

Page 37

Step 2: Remove fan retaining screws and

unplug from burner box.

Step 3: The combustion fan can now be

detached.

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 has been undertaken, it will be necessary to re-commission the heater as detailed in Section 3 of these instructions.

Step 4: Remove the fan orifice plate and

ducted air connection (If fitted).

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.

4.7 Radiant Tube Servicing

Step 1: Brush any dust from the exterior of the

tubes.

Step 2: Visually inspect inside the tubes. If

they are clean, skip to servicing the reflector.

Step 3: If required the interior of the tubes can

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

Doc No 700101 (06-15), Page 37

Page 38

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. Supply Voltage is 120VAC 60Hz

Is there power to the

burner?

CHECK: -

1. Transformer

YES

2. Integrity of wiring connections.

3. Light.

YES

Set thermostat to call for heat at maximum setting

Does the fan run?

CHECK: -

1. Integrity of wiring connections.

2. Pressure switch operation.

3. Ignition controller.

4. Transformer.

Do the amber

lights illuminate after a

purge period?

Is there power to

the fan?

Does the Pressure

switch close?

YES

CHECK: -

1. Voltage supply to fan terminal 120VAC 60Hz

2. Integrity of wiring connections.

3. Fan.

CHECK: -

1. Pressure switch wiring connections.

4. Integrity of wiring connections.

YES

5. Amber lights.

6. Ignition controller.

5. Transformer

YES

Doc No 700101 (06-15), Page 38

CHECK: -

1. Hose connection to Pressure switch.

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

3. Pressure switch operation.

4. Supply voltage 120VAC / 60Hz

5. Transformer.

6. Ignition Controller.

Page 39

To aid the troubleshooting 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 Flashes Combustion pressure switch closed with blower off 3 Flashes Lockout from the three ignition trials 4 Flashes Lockout from five flame losses 5 Flashes Control hardware fault detected 6 Flashes Lockout from five pressure switch losses

Doc No 700101 (06-15), Page 39

Page 40

6. Replacing Parts.

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

6.1 Burner Controller Replacement Step 1: Loosen screw in right hand burner

access door and open.

Step 2: Disconnect burner controller from the

wiring harness.

Step 3: Disconnect the spark lead from burner

controller.

6.2 Air Pressure Switch Replacement Step 1: Open left hand door. Disconnect the two

silicone tubes from the pressure switch.

Step 2: Remove the two screws shown below.

Step 4: Remove the two screws attaching the

controller to the burner door and remove.

Step 5: Attach new burner controller. Step 6: Re-attach leads. Step 7: Test product and close access door.

Step 3: Remove electrical connections. The air

pressure switch can now be removed.

Step 4: Fit the new air pressure switch ensuring

the silicone tubes are connected as shown below.

Step 5: Test product and close access doors.

Doc No 700101 (06-15), Page 40

Page 41

6.3 Gas Valve Replacement Step 1: Remove the burner assembly as

described in the servicing section.

Step 2: Open the right hand access door and

detach the burner controller from the wiring harness.

Step 3: Open the left hand access door and

detach the silicone hoses from the air pressure switch.

Step 6: Detach the two screws securing the

front of the gas valve.

Step 7: Remove the four screws (arrowed),

holding the rear burner plate in position.

Step 4: Remove the 4 screws holding the

burner head onto the burner assembly.

Step 5: The burner head can now be detached

by disconnecting the silicone tube and the burner head wiring.

Step 8: Remove the rear plate.

Step 9: The jet carrier, gas inlet, and wiring

harness can now be detached from the gas valve.

Step 10: The two screws retaining the gas valve

can now be removed.

Step 11: The gas valve can now be replaced. Step 12: Reattach all components. Step 13: Set pressures and test for reliable

burner performance.

Doc No 700101 (06-15), Page 41

Step 14: Close access door.

Page 42

Notes.

Doc No 700101 (06-15), Page 42

Page 43

Notes.

Doc No 700101 (06-15), Page 43

Page 44

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.

1. This appliance must only be installed by qualified installer 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 To Start the 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 and 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 700101 (06-15), Page 44

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. 700101

Reznor VPS150 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual