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

Form I-VPS (Version C) 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
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
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 - 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

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.

2.2.3 Brackets

Please read these assembly notes in

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

2.2.1 Tubes

There can be four types of brackets supplied
with these heaters:

 Type ‘H’ are suspension brackets with

Each heating unit has two types of emitter tube.
For details of the tube types 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 assemblers'
drawings.

Turbulators: Ensure that the correct

 Type ‘G’ are suspension brackets with

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

2.2.2 Turbulators (where fitted)

Insert turbulator into correct tube
as indicated in the assembly
drawings.

tube straps.

"A"

VIEW ON "A"

no tube straps.

15

 Type ‘F’ are fixed reflector brackets.

2 x SCREWS TIGHTENED TO FIX REFLECTOR

 Type ‘S’ are sliding reflector brackets.

2.2.4 Couplers

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

Slide the coupler over the tube ensuring that the
screw stop has butted up to the tube ends.
Using the 9/16” wrench to tighten the bolts.

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.

LEAVE 1/8" MIN. GAP TO ALLOW REFLECTOR TO SLIDE

Slip the suspension brackets onto the tube
assembly. The fixed suspension point ’H’
shown on the drawings are adjacent to the
burner and secures the first suspension bracket
to the tube with a tube strap. All other
suspension brackets ’G’ shown on the
drawings, have floating suspension points.

Reflectors are fixed at point ’F’ with a reflector
support bracket and reflectors are held in
position with fixing screws. Fixed and sliding
joints alternate along the heater at the spacings
indicated on the individual heater assembly
sheets.

DO NOT OVERTIGHTEN.

Moving between the four bolts, tighten each
ensuring that equal pressure is applied to each
bolt in turn. Complete assembly by drilling and
screwing self tapping retention zip screws.

2.2.5 Reflectors.

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

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

The first and second reflector are fixed at the
point F by a type F reflector support bracket and
are held in place by tightening the fixing screws.

Each subsequent reflector must

OVERLAP the previous one as shown

below and to a distance as indicated by
their individual assembly sheets.

Alternate fixings of further reflectors by type S
and type F reflector brackets and space as
indicated by individual assembly sheets.

Reflector support bracket assemblies
are fitted at each reflector joint, with the
clamp screws adjusted so that reflectors
are fixed together.

16

BURNER
ASSEMBLY

H

F

REFLECTORS

S

F

Typical usage of optional bend kits:

End Cap

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.

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.

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. This elbow
should be turned with the outlet facing either
side.

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 of the range of heaters.

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

Corner reflector

End Caps

Corner reflectors (optional)

16” crs

Corner reflectors kit

U Bend

End Caps

90° Bend

90° Elbow

15”

17

S20

S30

S40

S50

S60

S70

S80

Figure . 8. Possible Heater Orientations

U20

U40

U60

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.

U80

18

Figure 9. Heater Assembly: Model Linear 60-S20 and 80-S20.

END

CAPS

GH

(OPTIONAL)

6"-9" REFLECTOR OVERLAP

S

TURBULATOR

(SEE DETAIL)

TURBULATOR DETAIL PT. NO. 270495

NOTE: FOR MODEL 60/80 LP GAS ONLY

NOTE: FOR MODEL 80 NAT GAS ONLY

BURNER INSERT DETAIL PT. NO. 270489

2" MINIMUM

L

C

F

STANDARD 4" COUPLER

REFLECTOR OVERLAP

G

21'6½" NOMINAL OVERALL ASSEMBLED LENGTH

10' 3" REFLECTORS TYPICAL OF 2

SUSPENSION POINTS

DISTANCE BETWEEN

NO TO EXCEED 12'

CAPS

END

(OPTIONAL)

BURNER

COUPLER

SF

TUBE & REFLECTOR SUSPENSION BRACKET

DETAIL

2 x SCREWS MIN 1/8" GAP TO

BOLT

NUT &

SUPPLIED

REFLECTOR

H G

DETAIL

TUBE

RADIANT

(SEE DETAIL)

NAT GAS ONLY

BURNER INSERT

TUBE

STRAP

REFLECTOR

VIEW ON "A"

"A"

4"

6"

SUSPENSION

12.6" ref

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

FIRST SUSPENSION POINT TUBE STRAP

TUBE

STRAP

2 x SCREWS TIGHTEN TO

ALLOW REFLECTOR TO SLIDE

FIX REFLECTOR

DETAIL

SLIDING REFLECTOR BRACKET

DETAIL

FIXED REFLECTOR BRACKET

19

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

END

CAPS

(OPTIONAL)

6" REFLECTOR OVERLAP

S F

GGH

BURNER INSERT DETAIL PT. NO. 270489

NOTE: FOR MODELS 80/100 NAT GAS ONLY

COUPLER

2" MINIMUM

L

C

STANDARD 4" COUPLER

REFLECTOR OVERLAP

6" REFLECTOR OVERLAP

F

31'6½" NOMINAL OVERALL ASSEMBLED LENGTH

G

DISTANCE BETWEEN

COUPLER

(SEE DETAIL)

NAT GAS ONLY

BURNER INSERT

TUBE

STRAP

SUSPENSION POINTS

10' 3" REFLECTORS TYPICAL OF 3

NO TO EXCEED 12'

REFLECTOR

VIEW ON "A"

"A"

TUBE & REFLECTOR SUSPENSION BRACKET

G

DETAIL

H

S

DETAIL

ALLOW REFLECTOR TO SLIDE

2 x SCREWS MIN 1/8" GAP TO

SLIDING REFLECTOR BRACKET

BOLT

NUT &

SUPPLIED

REFLECTOR

F

CAPS

END

(OPTIONAL)

BURNER

DETAIL

4"

6"

12.6" ref

SUSPENSION

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

FIRST SUSPENSION POINT TUBE STRAP

TUBE

RADIANT

TUBE

STRAP

DETAIL

2 x SCREWS TIGHTEN TO

FIX REFLECTOR

FIXED REFLECTOR BRACKET

20

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

END

CAPS

(OPTIONAL)

3" REFLECTOR

OVERLAP

F

G

BURNER INSERT DETAIL PT. NO. 270489

NOTE: FOR MODELS 80/100 NAT GAS ONLY

41'6½" NOMINAL OVERALL ASSEMBLED LENGTH

G GH

G

DISTANCE BETWEEN

SUSPENSION POINTS

NO TO EXCEED 12'

6" REFLECTOR

OVERLAP

S S

L

C

STANDARD 4" COUPLER

2" MINIMUM

REFLECTOR OVERLAP

COUPLER COUPLER

6" REFLECTOR

OVERLAP

TYPICAL OF 4

10' 3" REFLECTORS

F

DETAIL

2 x SCREWS MIN 1/8" GAP TO

*(HIGH TEMP COUPLER

COUPLER

MODEL 125/150 )

TUBE

STRAP

(SEE DETAIL)

BURNER INSERT

NAT GAS ONLY

4"

6"

REFLECTOR

"A"

TUBE & REFLECTOR SUSPENSION BRACKET

BOLT

NUT &

SUPPLIED

VIEW ON "A"

REFLECTOR

H G

SF

DETAIL

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

CAPS

END

(OPTIONAL)

BURNER

SUSPENSION

21

BRACKET

2 x SCREWS TIGHTEN TO

FIX REFLECTOR

DETAIL

FIXED REFLECTOR BRACKET

DETAIL

TUBE

RADIANT

FIRST SUSPENSION POINT TUBE STRAP

TUBE

RADIANT

SUPPLIED

NUT & BOLT

TUBE

STRAP

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

END

CAPS

(OPTIONAL)

51'6½" NOMINAL OVERALL ASSEMBLED LENGTH

3" REFLECTOR

OVERLAP

G

S

COUPLERCOUPLER

F

3" REFLECTOR

OVERLAP

BURNER INSERT DETAIL PT. NO. 270489

NOTE: FOR MODEL 100 NAT GAS ONLY

G

2" MINIMUM

L

C

S F

STANDARD 4" COUPLER

6" REFLECTOR

OVERLAP

REFLECTOR OVERLAP

G GH

*(HIGH TEMP

COUPLER

COUPLER

MODEL 170 & 200)

SF

F

6" REFLECTOR

OVERLAP

G

* (HIGH TEMP

COUPLER

COUPLER

MODELS 125,

150, 170 & 200)

DETAIL

2 x SCREWS MIN 1/8" GAP TO

TUBE & REFLECTOR SUSPENSION BRACKET

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

DETAIL

POINTS NOT TO

EXCEED 12'

END

10' 3" REFLECTORS

CAPS

(OPTIONAL)

SUSPENSION

DISTANCE BETWEEN

TYPICAL OF 5

BURNER

TUBE

STRAP

4"

(SEE DETAIL)

BURNER INSERT

6"

NAT GAS ONLY

REFLECTOR

VIEW ON "A"

"A"

SUSPENSION

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

H G

DETAIL

FIRST SUSPENSION POINT TUBE STRAP

BOLT

NUT &

SUPPLIED

REFLECTOR

DETAIL

2 x SCREWS TIGHTEN TO

TUBE

RADIANT

TUBE

STRAP

FIX REFLECTOR

FIXED REFLECTOR BRACKET

22

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

END

CAPS

(OPTIONAL)

3" OVERLAP

S

F

G GH

COUPLERCOUPLER

3" OVERLAP

S

GGG

COUPLER

3" OVERLAP

F

L

C

2" MINIMUM

STANDARD 4" COUPLER

6" OVERLAP

61'6½" NOMINAL OVERALL ASSEMBLED LENGTH

S

REFLECTOR OVERLAP

SF

2 x SCREWS MIN 1/8" GAP TO

2 x SCREWS TIGHTE N TO

DETAIL

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

DETAIL

FIX REFLECTOR

FIXED REFLECTOR BRACKET

DETAIL

*(HIGH TEMP

COUPLER

COUPLER

MODELS 170 & 200)

6" OVERLAP

G

SUSPENSION

DISTANCE BETWEEN

POINTS NOT TO

EXCEED 12'

TYPICAL OF 6

10' 3" REFL'S

F

TUBE

STRAP

REFLECTOR

*HT COUPLER

4"

6"

"A"

TUBE & REFLECTOR SUSPENSION BRACKET

BOLT

NUT &

SUPPLIED

VIEW ON "A"

REFLECTOR

H G

DETAIL

TUBE

RADIANT

CAPS

END

(OPTIONAL)

SUSPENSION

BRACKET

TUBE

BURNER

RADIANT

SUPPLIED

NUT & BOLT

FIRST SUSPENSION POINT TUBE STRAP

TUBE

STRAP

23

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

END

CAPS

(OPTIONAL)

F

3" OVERLAP

S

G GH

3" OVERLAP

F

G

3" OVERLAP

GGG

3" OVERLAP

S

2" MINIMUM

L

COUPLER COUPLER COUPLERCOUPLER

F

STANDARD 4" COUPLER

C

REFLECTOR OVERLAP

71'6½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN

6" OVERLAP

6" OVERLAP

G

SUSPENSION

POINTS NOT TO

EXCEED 12'

TYPICAL OF 7

10' 3" REFL'S

CAPS

END

(OPTIONAL)

S

DETAIL

2 x SCREWS MIN 1/8" GAP TO

200)

*(HT COUPLERS

COUPLER

MODELS 170 &

F

TUBE

STRAP

REFLECTOR

HT COUPLER

4"

6"

SUSPENSION

BRACKET

BURNER

SUPPLIED

"A"

TUBE

RADIANT

NUT & BOLT

TUBE & REFLECTOR SUSPENSION BRACKET

BOLT

NUT &

SUPPLIED

VIEW ON "A"

FIRST SUSPENSION POINT TUBE STRAP

REFLECTOR

H G

DETAIL

TUBE

RADIANT

TUBE

STRAP

2 x SCREWS TIGHTEN TO

SF

DETAIL

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

DETAIL

FIX REFLECTOR

FIXED REFLECTOR BRACKET

24

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

END

CAPS

(OPTIONAL)

S

3" OVERLAP

F

G

3" OVERLAP

S

G

3" OVERLAP

F

G GH

3" OVERLAP

GGG

S

L

C

STANDARD 4" COUPLER

2" MINIMUM

REFLECTOR OVERLAP

3" OVERLAP

F

81'6½" NOMINAL OVERALL ASSEMBLED LENGTH

COUPLER COUPLER COUPLER COUPLER COUPLER

6" OVERLAP

S

DETAIL

2 x SCREWS MIN 1/8" GAP TO

SF

DETAIL

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

TUBE & REFLECTOR SUSPENSION BRACKET

HT COUPLER

6" OVERLAP

F

TUBE

STRAP

NUT &

BOLT

SUPPLIED

REFLECTOR

G

HT COUPLER

4"

TYPICAL OF 8

SUSPENSION POINTS

DISTANCE BETWEEN

NO TO EXCEED 12'

10' 3" REFL'S

CAPS

END

(OPTIONAL)

6"

SUSPENSION

BRACKET

SUPPLIED

BURNER

NUT & BOLT

VIEW ON "A"

"A"

FIRST SUSPENSION POINT TUBE STRAP

TUBE

RADIANT

REFLECTOR

H G

2 x SCREWS TIGHTEN TO

DETAIL

FIX REFLECTOR

FIXED REFLECTOR BRACKET

DETAIL

TUBE

RADIANT

TUBE

STRAP

25

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

3' 3"

12'1½" NOMINAL OVERALL ASSEMBLED LENGTH

F

G

COUPLER

10' 3" REFLECTORS TYPICAL OF 2

F

GH

BURNER INSERT DETAIL PT. NO. 270489

NOTE: FOR MODEL 80 NAT GAS ONLY

2" MINIMUM

BURNER INSERT

DISTANCE BETWEEN

(SEE DETAIL)

SUSPENSION POINTS

NAT GAS ONLY

STANDARD 4" COUPLER

DETAIL

NO TO EXCEED 12'

L

C

REFLECTOR OVERLAP

G

CAPS

END

(OPTIONAL)

BURNER

TUBE & REFLECTOR SUSPE NSION BRACKET

4"

6"

TUBE

STRAP

REFLECTOR

VIEW ON "A"

"A"

SUSPENSION

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

H G

DETAIL

FIRST SUSPENSION POINT TUBE STRAP

BOLT

NUT &

SUPPLIED

REFLECTOR

TUBE

RADIANT

TUBE

STRAP

2 x SCREWS TIGHTEN TO

F

DETAIL

FIX REFLECTOR

FIXED REFLECTOR BRACKET

26

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

3' 3"

S

GGG

COUPLER

F S

6"-9" REFLECTOR OVERLAPS

G

BURNER INSERT DETAIL PT. NO. 270489

NOTE: FOR MODELS 80/100 NAT GAS ONLY

2" MINIMUM

L

C

F

STANDARD 4" COUPLER

REFLECTOR OVERLAP

GH

22'1½" NOMINAL OVERALL ASSEMBLED LENGTH

SF

DISTANCE BETWEEN

END

SUSPENSION POINTS

CAPS

DETAIL

*(HIGH TEMP

COUPLER

COUPLER

MODEL 125/150 )

2 x SCREWS MIN 1/8" GAP TO

TUBE & REFL ECTOR SUSPENSION BRACKET

(SEE DETAIL)

NAT GAS ONLY

BURNER INSERT

NO TO EXCEED 12'

10' 3" REFLECTORS TYPICAL OF 4

4"

(OPTIONAL)

BURNER

6"

TUBE

STRAP

REFLECTOR

VIEW ON "A"

"A"

SUSPENSION

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

H G

DETAIL

FIRST SUSPENSION POINT TUBE STRAP

BOLT

NUT &

SUPPLIED

REFLECTOR

TUBE

RADIANT

TUBE

STRAP

2 x SCREWS TIGHTEN TO

ALLOW REFLECTOR TO SLIDE

FIX REFLECTOR

DETAIL

SLIDING REFLECTOR BRACKET

DETAIL

FIXED REFLECTOR BRACKET

27

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

3' 3"

F

G

S

6" REFLECTOR OVERLAPS

G

GGH

S

G

*(HIGH TEMP

COUPLER

COUPLER

MODELS 170 &

2" MINIMUM

200)

STANDARD 4" COUPLER

L

C

REFLECTOR OVERLAP

32'1½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN

G

G

END

F F

SUSPENSION POINTS

CAPS

NO TO EXCEED 12'

(OPTIONAL)

6"-9" REFLECTOR OVERLAPS

10' 3" REFLECTORS TYPICAL OF 6

BURNER

F

SF

DETAIL

2 x SCREWS MIN 1/8" GAP TO

TUBE & REFLECTOR SUSPENSION BRACKET

HT COUPLER

TUBE

STRAP

REFLECTOR

VIEW ON "A"

"A"

4"

6"

SUSPENSION

BRACKET

TUBE

RADIANT

SUPPLIED

NUT & BOLT

H G

DETAIL

FIRST SUSPENSION POINT TUBE STRAP

BOLT

NUT &

SUPPLIED

REFLECTOR

TUBE

RADIANT

TUBE

STRAP

2 x SCREWS TIGHTEN TO

DETAIL

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

DETAIL

FIX REFLECTOR

FIXED REFLECTOR BRACKET

28

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

3' 3"

S

GGG

F

3" REFLECTOR OVERLAPS

G

S

6" REFLECTOR OVERLAPS

G

GGH

F

G

COUPLER

S

2" MINIMUM

G

STANDARD 4" COUPLER

L

C

REFLECTOR OVERLAP

42'1½" NOMINAL OVERALL ASSEMBLED LENGTH

DISTANCE BETWEEN

END

SUSPENSION POINTS NO TO

F S

CAPS

HT COUPLER

6"-9" REFLECTOR OVERLAPS

EXCEED 12'

10' 3" REFLECTORS TYPICAL OF 8

(OPTIONAL)

BURNER

F

DETAIL

2 x SCREWS MIN 1/8" GAP TO

TUBE & REFLECTOR SUSPENSION BRACKET

TUBE

STRAP

REFLECTOR

HT COUPLER

SUSPENSION

4"

6"

BRACKET

SUPPLIED

NUT & BOLT

VIEW ON "A"

"A"

TUBE

RADIANT

H G

DETAIL

FIRST SUSPENSION POINT TUBE STRAP

REFLECTOR

RADIANT

SUPPLIED

TUBE

BOLT

NUT &

TUBE

STRAP

ALLOW REFLECTOR TO SLIDE

SLIDING REFLECTOR BRACKET

2 x SCREWS TIGHTEN TO

FIX REFLECTOR

FIXED REFLECTOR BRACKET

SF

DETAIL

DETAIL

29

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. Remove burner and inspect the
electrode assemblies ensuring these are
securely fixed and all electrical connections
securely made.

Re-fit the burner ensuring that it is correctly
positioned and the screws are fully tightened.
Ensure that electrical and gas supplies are
isolated.

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

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

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

Open the manual gas valve outside the control
housing

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

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

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

If ignition is unsuccessful the gas valve will close
and the spark ignition de-energized after
approximately 15 seconds.

For approximately 30 seconds the fan will purge
the system then re-ignition will be attempted.
After 2 further attempts at ignition the control
unit will ‘lock-out’, the ‘power on’ lamp will
remain illuminated and the fan will 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 manometer to the pressure
test point provided on the combination gas
control valve.

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

Manometer

Multimeter

30

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.

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

Check the operation of the flame safeguard
equipment as follows:

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

Check the operation of the pressure proving
switch as follows:

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

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

Close the controls door securing it with the
screw.

31

Commissioning chart

Check installation has

been carried out to these

instructions.

Remove burner from tube and inspect burner head.

Replace burner on tube

and secure.

Check thermostat is set to

maximum and is calling

for heat.

Ensure gas and electricity

supplies are isolated.

(See servicing instructions)

Reconnect gas hose.

Open manual valve.

Check soundness.

Switch on electrical supply.

The red 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 a responsible person.

A successful ignition is indicated

by the amber light illuminating

and remaining illuminated.

Close control housing

Turn off power and check

that all components are

securely fastened.

NO

Has the

burner lit?

YES

Check operation on flame failure.

Check gas pressure.

Check operation of

air pressure switch.

32

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
to complete the tasks laid out in this manual.

Leather
Faced
Gloves

½”
Wrench

Phillips
Screwdriver

5/32”
(4mm)
Allen

4.2 Burner Description.

Figure 20. Burner breakdown

K

A

Suitable alternative tools may be used.

Small Flat
Head
Screwdriver

Manometer

Multimeter

J

H

Large Adjustable
wrenches for fitting
of Gas Flex.

Soft
Brush

L

F

G

I

A Ignition Controller

B Gas Valve

C Power On Red LED

D Burner On Yellow LED

F Burner Tube

G Burner head

H Injector

I Igniter Assembly

Q

P

M

J Jet Carrier

K Combustion Fan

L Pressure Switch

M Gaskets

N Transformer

P Burner Orifice Plate

Q Flame Plate (not shown)

D

C

N

Note: Cables Omitted
For Clarity

B

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 be-

low, taking care to support the burner
connection.

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.

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

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.

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.

34

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 below. This can be cleaned
together with the Inside of the burner head.

the two screws and separating the igniter lead
connectors.

Step 4: Refit the electrode assembly and en-

sure 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 holes on the outer ring
are aligned alongside the probes.

Step 3: The condition of the igniter assembly

can be checked for deterioration. However, we
advise replacement at each service to ensure
continued reliability. Detach the electrode
assembly from the burner head by removing

35

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.

36

5. Spare Parts.

Required Spares

In order to aid troubleshooting and servicing we
recommend that the components shown in this
section should be stocked.

Note: Any spare part components that are

not approved by the manufacturer could
invalidate the approval of the appliance and the
warranty.

Item

Transformer
(30VA)

Gas Valve
NG
LPG

Flame Plates
Models
60 NG & LPG
80 / 100 LPG
125 / 150 LPG
170 LPG

Jet Carriers
Models
60 - 150 NG
60 - 170 LPG
Model
170/200 NG

Part No. Description Part No. Description Item

175265

270378
270496

269957
269958
269959
269960

270375

270376

Pressure Switch
Models 60 - 170
Model 200 NG

Single Probe
Ignitor with
Connector Lead

Amber Neon
(Burner On)

Red Neon
(Power On)

24V UT Ignition
Controller

270386
270387

270441

270473

270474

204955

Burner Head

Burner Tube

Turbulators
Models
60 / 80 LPG S20

Burner Insert
Models
80 / 100 NG

270425

270424

270495

270489

Injector

Combustion Fans
Models
60 - 170 NG,
60 - 150 LPG
Models
200 NG,
170 LPG

See
section 1.8

270464

270467

37

6. Troubleshooting Guide.

START

Ensure gas & electricity

supplies are enabled.

Turn any external timer

to call for heat (if fitted).

YES

Does the Power On

light illuminate?

NO

CHECK: -

1. Operation of any timer or control.

2. External fuses.

3. Supply Voltage is 120VAC 60Hz

Is there power to the

burner?

NO

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?

NO

NO

Is there power to

the fan?

NO

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

NO

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.

38

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

39

7. Replacing Parts.

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

7.1 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.

7.2 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: Reattach 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 silicon tubes are connected as shown
below.

Step 5: Test product and close access doors.

7.3 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 silicon 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 silicon 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.

Step 14: Close access door.

7.4 Optional Extra Kits.

180° U-Bend Kit

(1 Off)

90° Elbow Kit

Kit (1Pair)

Aluminized

Steel End Cap

Air inlet Kit

Combustion

Conversion Kit

Propane Gas &

Propane Altitude

270630 270619

Conversion Kit

Natural Gas Altitude

270613 270611 270277 270276

270630 270620

270631 270621

270632 270622

270633 270623

270634 270627*

270635 270628**

60

MODEL

42

80

100

125

150

170

200

* Burner de-rated when converted to propane

** Burner de-rated when converted to propane. Not for use at altitude.

Notes.

43

8. 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.

8.1 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 switch
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. 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.

8.2. To Switch Off Heater

Switch off electrical supply to the heater.

The burner will stop and the fan will shut off.

8.3. 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.

800-695-1901

www.RezSpec.com

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Trademark note: Reznor is registered in at least the United States.

All other marks are the property of their respective organizations.
0114 OG POD Form I-VPS ( Version C.1)

700101