Welcome to the new range of powered HiLo
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.
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 Emitter 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
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.
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 Emitter 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
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 present.
B. Heaters can be suspended horizontally or at
any angle along the axis of the tubes but
can only be rotated about the burner head 0
to 55°. See section 1.3 for clearance
dimensions.
Doc No 700106 (06-15), Page 2
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 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)
above sea level for the US and 0 - 4500 ft
(1370m) above sea level for Canada.
Conversion kits are available for 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. have
to be designed and produced in accordance
with sound engineering practices. 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 emitter
tube/bracket/reflector has been completed.
Longer tube assemblies may be raised in more
than one sub-assembly with final emitter tube
connection made in the air.
Ensure that the installer uses the burner roof
support mounting bracket when suspending the
heater. This is situated on the front of the
burner. When packed the bracket is reversed
and must be turned to its correct state for
mounting. (ref page 15)
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.
U TUBE VARIANTS
NOTE.
'S' HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
SUITABLE CHAIN
WORKING LOAD
LIMIT 100LB
EXHAUST
END
CHAIN
55° SUSPENSION
Figure 1. Recommended Methods of Heater Suspension.
Doc No 700106 (06-15), Page 3
BURNER
END
ON VENTED HEATERS, THE HEATER SHOULD SLOPE DOWNWARDS AWAY FROM
THE BURNER AND ON UNVENTED HEATERS SHOULD SLOPE DOWNWARDS
TOWARDS BURNER BY APPROX. ½” FOR HORIZONTAL INSTALLATIONS AS SHOWN
BELOW (DIAGRAMS EXAGGERATED FOR CLARITY)
1/2”
VENTED
1/2”
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.
Table 1
MODEL A A1 / A2 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
74
(188)
29
(74)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
15° = 72 (183)
25° = 68 (173)
100
74
(188)
35° = 61 (155)
45° = 53 (135)
32
(82)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
16
(41)
12
(31)
55° = 43 (110)
125
150
170
74
(188)
74
(188)
86
(219)
15° = 82 (209)
25° = 78 (199)
39
(99)
39
(99)
48
(122)
47
(120)
48
(122)
48
(122)
20 (51) /
10* (26)*
20 (51) /
10* (26)*
20 (51) /
10* (26)*
8
(21)
8
(21)
11
(28)
22
(56)
22
(56)
22
(56)
20
(51)
20
(51)
20
(51)
18
(46)
18
(46)
20
(51)
12
(31)
12
(31)
12
(31)
35° = 71 (181)
45° = 61 (155)
200
* distance with end caps fitted.
86
(219)
WARNING:
55° = 50 (127)
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(31)
maintained. Signs should be posted in storage areas to specify maximum stacking height to
maintain required clearance to combustibles. Such signs must either be posted adjacent to
the heater thermostats or in the absence of such thermostats in a conspicuous location.
Refer to mounting clearance tables.
Doc No 700106 (06-15), Page 4
Figure 2 Clearance to Combustibles (Standard indoor reflectors)..
The minimum clearances to combustible materials are given in Table 1 These minimum
distances MUST be adhered to at all times. Adequate clearance MUST be provided around air
openings into the combustion chamber and there MUST be suitable clearance for accessibility and
for combustion / ventilating air supplies.
D2
A2
.
0° to 55°
Angled view.
Return end on
U tube heater
A1
C3
WARNING!
combustion and ventilation air supply.
provision in the building for
Ensure that there is adequate
Installation must meet minimum
B
requirements and applicable codes.
Below
A
Outlet end.
heater
D1
End
B1
Side
unvented
unvented
unvented
Above outlet
Above
Reflector
C2
Burner end.
B
Side
Doc No 700106 (06-15), Page 5
vented
End view.
C1
Above
Burner
Above
C1
Burner
E
E
Service
distance
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 3. 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 pipe bend
diameter of 12” (30cm) and pipe displacement
distance of 3” (7.62cm).
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
* 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 150,000Btu/h and above, ¾” ID x 36” long
NOTE: For Canada all heaters MUST use a hose 36” long
(See Table 3)
Table 3
HOSE SIZE USA CANADA
3/4” CE4
CONTACT
FACTORY
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 700106 (06-15), Page 6
CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. FOR HEATERS UP
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
Min Required Gas Pressure (in W.C)
Max Supply Pressure (in W.C)
Natural Gas LP/Propane Gas
7.0 11.0
14.0 14.0
Gas Supply Connection ½” N.P.T thread
1.5 Electrical Connections
Important: All electrical work should be done by a
qualified electrician in strict accordance with the
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.
National Electrical Code ANSI/NFPA 70 or
Canadian Codes CSA C22.1.
The electrical supply to
the heater is by three
wires: hot (Live), neutral
and ground connections.
Install in accordance with
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)
all state & local codes.
Where alternative
manufacturers controls
are used, please refer to
their instructions for their
installation details.
Fuse: external 3 amp.
Figure 5. External Wiring Schematic
Burner 1
BK
BL
R
O
120V AC
Supply
24V AC
Terminals
(120V AC Fan
Terminals)
BK
G
W
Doc No 700106 (06-15), Page 7
R
C
W1
W2
F1
F2
E
N
L
E
N
24V AC 2-Stage
Thermostat (Ext.)
W1 W2
RC
KEY:
BK-BLACK
BL-BLUE
R-RED
O-ORANGE
G-GREEN
W-WHITE
Notes:
Use 18/4 class 2 thermostat cable
between heater and thermostat.
Max. length @ 18 Awg (0.8mm²) =
100ft.
Only one burner can operate from
one thermostat as supplied.
When servicing heaters ensure
the electricity supply is isolated
from the mains supply.
120V AC supply is still present at
each burner when the thermostat
is switched off.
Figure 6a. Internal Burner Wiring Diagram.
24V Two stage
Thermostat
R
BR
24V AC Stat
Terminals
R
BR
YY
Pressure Switch
E
LN
W2W1
C
G
O
BL
120V AC Fan
W
BK
120V AC
G
R
K
Terminals
W2W1
C
O
BL
F1NEF2
K
G
R
W
BK
BK
Supply
LNE
G
BK
W
KEY:
BL - BLUE
BK - BLACK
W
BR - BROWN
GR - GREY
G - GREEN
E
E
K - PINK
R - RED
W - WHITE
Y - YELLOW
BK
120V/24VAC 60Hz
Transformer
BR
W
O - ORANGE
P - PURPLE
Power ON (red)
BLBR
High Fire
Low Fire
Relay
R
1222
A2
24V AC
RELAY
21
NC
A1
COIL
1424
NO
11
COM
BL
BK
R
Y
Y
P
R
BK
L1
IND
MV
O
BR
R
W1
PS1
PS0
BR
BL
GR
X
C
COM
Gas Control
(amber)
High Fire
P
M
GR
C
K
HI
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.
Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C
PGR
KGR
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
Doc No 700106 (06-15), Page 8
1.5.1 Multiple burner configurations (Master
& Slave) via Optional Relay .
Refer to figure 6b and 6d.
Multiple VPT burners can be controlled via one
main burner. In this scenario the main burner is
knows as the ‘Master’ and any additional
burners are known as ‘Slaves’.
The external two stage thermostat is connected
to the Master burner and powered via the inbuilt
transformer. The total burner load for the Master
is 20VA. Each additional ‘Slave’ burner is 1.6VA
The Thermostat chosen to control the multiple
heaters must not have a power requirement
exceeding the spare capacity as shown in the
examples below:
CONFIGURATION TOTAL BURNER LOAD SPARE FOR THERMOSTAT
Master PLUS 1 Slave 21.6VA
Master PLUS 3 Slaves 24.8VA
Master PLUS 5 Slaves 28.0VA
Master PLUS 7 Slaves 31.3VA
Figure 6b. Wiring schematic. Multiple Burners Master and Slave.
GND
L2
L1 (HOT)
120V 60Hz 1 Ph
Supply circuit
R
C
W1
W2
MASTER
BURNER
W1
W2
R
C
THERMOSTAT
24VAC 60Hz 1 Ph Hi/Lo circuit
1.5.2 Multiple burner configuration via
independently powered two stage
thermostats. Refer to figures 6c and 6d.
Note: If the thermostat has an independent
power supply, all burners in the zone to be
controlled MUST be Slave burners.
The maximum number of Slave burners per
thermostat is dependent on the maximum
power output of the thermostat selected.
LEN
SLAVE
BURNER
W1 W2
Each ‘Slave’ burner is rated at 1.6VA 24VAC
60Hz.
The external two stage thermostat is powered
via its own power supply and must output to
each Slave burner - 24VAC for low fire to
terminal W1 and 24VAC for hi fire to both
terminals W1 and W2
Refer to thermostat manufactures literature for
details.
18.4VA
15.2VA
12.0VA
8.8VA
LENLENLEN
SLAVE
BURNER
W1 W2W1 W2
SLAVE
BURNER
Figure 6c. Wiring schematic. Multiple Burners via independently powered Relay.
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.
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 700106 (06-15), 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 gases 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.
recommended vent length is 25ft (7.6m) with
a maximum of two elbows
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.
The maximum recommended vent length is
25ft (7.6m) with a maximum of two 90°
elbows.
However runs up to 12ft (3.6m) can
use 4” (101mm) vent pipe. Runs over 12ft
(3.6m) should always 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 manufacturer.
Standard vent terminals must extend at least
6” (152mm) from the wall and at least
The maximum
. All connections
24” (609mm) from any combustible overhang.
This protects the building material from
degradation by the vent gases.
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) diameter 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 700106 (06-15), 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.
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 700106 (06-15), Page 12
1.8 Technical Details - Table 5
No of Injectors
Gas Connection
Electrical Supply
Vent size (in)
Unitary Fan Motor Details
Current Rating
Ignition
Natural Gas LP Gas
MODEL
High / Low High / Low
60
80
100
125
150
60,000/48,000 60,000/48,000
80,000/60,000 80,000/60,000
100,000/75,000 100,000/75,000
123,500/95,000 125,000/95,000
150,000/100,000 150,000/100,000
1
½” N.P.T
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
Min. Heater
Length
Max. Heater
Length
S ft S ft U ft U ft
20 40 20 40
30 40 40 40
30 40 40 40
30 50 40 40
40 60 40 60
170
200
169,000/125,000 169,000/125,000
200,000/160,000
N/A
50 70 60 60
50 70 60 60
Appliances can be installed up to 10,000ft above sea level in the USA. Altitude conversion kits are
available on request.