Model VPS
Burner/Control Box
with 20 - 80 ft Tube/Reflector Length
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
D. The unit shall be electrically grounded in
E. The heater may be installed in aircraft
Aircraft Hangars, ANSI/NFPA 409 and in
automotive garages when installed in
2
codes, with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas
and Propane Installation Code, CSA
B149.1.
accordance with National Electric Code
ANSI/NFPA 70 and Canadian Electrical
Code CSA C22.1.
hangars in accordance with the Standard for
accordance with the Standard for Parking
CHAIN
55° SUSPENSION
2/0 GA CHAIN
(TWISTED LINK, PLATED)
NOTE.
HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
EYE HOOKS
EXHAUST
END
BURNER
END
U TUBE VARIANTS
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.
Suitable Chain
Working Load Limit
100lb.
3
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 FOR 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.
Building material with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.) may be subject to
degradation at lower temperatures.
It is the installer’s responsibility to assure that adjacent materials are protected from degradation.
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be
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
C2
C1
A
B1
B
B
A
E
D2
.
D1
Ensure that there is adequate
provision in the building for
combustion and ventilation air supply.
Installation must meet minimum
requirements and appliciable codes.
Burner end.
Outlet end.
Angled view.
End view.
C3
Below
heater
Side
vented
Side
unvented
End
unvented
Above outlet
unvented
Above
Reflector
Above
Burner
Service
distance
Return end on
U tube heater
WARNING!
0° to 55°
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.
applicable
5
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 GasLP/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)
5.0 11.0
7.0 11.0
Max Supply Pressure (in W.C) 14.014.0
Gas Supply Connection ½” N.P.T thread
1.5 Electrical Connections
The electrical supply to the heater is by three
wires: live, neutral and ground 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
Install in accordance with all state & local codes.
Where alternative manufacturers controls are
used, please refer to their instructions for their
installation details.
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.
77
Supply circuit
120V 60Hz 1 Ph
L2
L1 (HOT)
GND
other burners
Burner 1
T
110V Thermostat
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
BK
R
Y
K
BR
GR
BL
K
Y
R
T
24V Thermostat
RW1
C
X
METHOD:Cut and strip pink cables linking terminals W1 and R
Attach thermostat wires using suitable wire nuts.
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
K - PINK
R - RED
Y - YELLOW
Supply circuit
120V 60Hz 1 Ph
S-0700
C
40VA
Trans
Relay
L1
G
R
L2
L2
L1 (HOT)
GND
T
24V Thermostat
other burners
Burner 1
RW1
C
Fan center relay
(Suppled by others)
Figure 5a. Single and Multiple Heater Installations 120V Control
KEY:
T
G
W
BK
G-GREEN
W-WHITE
BK-BLACK
120V Thermostat
BK
W
BK
G
Figure 5b. Single Heater Installations 24V Control
Other burners
Figure 5c. Multiple Heater Installations 24V Control
8
KEY:
G - GREEN
W - WHITE
BK - BLACK
R - RED
T
BK
W
30
BK
W
T
G R
BK
Other burners
Figure 6. Internal Burner Wiring Diagram.
LN
G
120V AC Fan
120V/60Hz AC
Supply
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
Gas Valve
C
M
E
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
Pressure Switch
120v/24VAC 60Hz
Transformer
Power ON (red)
Burner ON (amber)
BK
R
Y
K
BR
GR
BL
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
R - RED
W - WHITE
Y - YELLOW
K
Y
R
YY
R
W
G
BK
W
G
BLBR
RGR
R
GR
G
BR
BL
W
BK
G
E
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.
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.
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.
10
REFLECTOR
END OF RADIANT TUBE
VENT ADAPTOR ELBOW
12'-0" (3.66m)
12'-0" (3.66m)
(APPROXIMATE
MAXIMUM DIMENSIONS)
CODE APPROVED VENT
THROUGH ROOF
SEAL
SUPPLIED BY OTHERS
ROOF
4" (101mm) O.D. OR
HIGH TEMPERATURE SILICONE
SEAL JOINTS WITH
REQUIRED ONLY FOR 6" (152mm) DIA. VENT
4" (101mm) TO 6" (152mm) DIA. ALUMINUM ADAPTER
6" (152mm) O.D. FLUE
ALUMINUM
RADIANT
TUBE
REFLECTOR
4" (101mm) TO 6" (152mm) DIA. ALUMINUM ADAPTER
TERMINAL
6" (152mm)
COLLAR
SEAL JOINTS WITH
HIGH TEMPERATURE
WALL
REQUIRED ONLY FOR 6" (152mm) DIA. VENTS
ALUMINUM 4" (101mm) O.D. MAXIMUM LENGTH = 12'-0" (3.66m)
ALUMINUM 6" (152mm) O.D.MAXIMUM LENGTH = 25'-0" (7.62m)
(PLUS A MAXIMUM OF 2 x 90° BENDS
END OF
SUPPLIED BY OTHERS
COUPLER
SILICONE
INLET WITH
BIRD SCREEN
36" (914mm) MIN CENTERS
ALUMINUM 4" (101mm) O.D. PIPE
CLAMPS
4" (106mm) O.D. FLEXIBLE DUCT
BURNER
MAX LENGTH = 25'-0" (7.62m) WITH 2-90° LONG RADIUS BENDS
INLET WITH
6" (152mm)
SEAL JOINTS WITH
SILICONE OR DUCT TAPE
WALL
BIRD SCREEN
TERMINAL
36" (914mm) MIN CENTERS
Figure 7.a Vertical Venting.
Figure 7.b Horizontal Venting.
APPROVED CAT III VENT PIPE
CAT III ADAPTER
VENT CAT III ELBOW
Figure 7.c Fresh Air Ducted Intake.
APPROVED CAT 3 VENT PIPE
ELBOWS
WITH TWO– 90° ELBOWS
4.25” (108mm) O.D FLEXIBLE DUCT
ENSURE ALL JOINTS ARE
SEALED
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
Figure 7.d Wall Terminal Intake Kit.
11
1.8 Technical Details - Table 5
No of Injectors 1
Gas Connection ½” N.P.T
Electrical Supply 120 volt 1 phase 60Hz
Vent size (in) 4” or 6” (101mm or 152mm)
Unitary Fan Motor Details 120 volt 1 phase 60Hz
Current Rating 1.2A MAX
Ignition Electronic Program Start up with Spark Ignition
1 All standard units fitted with unvented vent, natural gas and aluminized steel reflectors.
2 1 off 180° bend (U) or upto 2 off 90° bends (L) can be fitted at no less than 50% of the total heater length.
3 4” (101mm) or 6” (152mm) vent terminal.
4 Combustion air kit.
5 Reflector end caps.
6 Altitude conversion kit.
7 Propane and propane altitude conversion kit.
14
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