Thomas & Betts TR, TR-H Installation Manual

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Page 1

Gas-Fired T ubular,

Radiant, Low-Intensity

Infrared Heater

INST ALLA TION FORM RZ-NA-I-TR

Obsoletes Form 456 (Version B)

APPLIES TO: INFRA-REZ® Heater Models TR/TR-H

Table of Contents

Paragraph No. Page Paragraph No. Page

GENERAL................................................................................................. 1

HEATER INSTALLATION............................................................... 1-21

1A. Installation Codes ............................................................................... 2

1B. Warranty .............................................................................................. 2

2. Description/General .............................................................................. 2

3. Specifications ........................................................................................ 3

4. Clearances to Combustibles ................................................................. 3

5. Location and Mounting Height .......................................................3- 4

6. Uncrating/Packaging ............................................................................ 4

7. High Altitude Operation ....................................................................... 5

8. Suspension Dimensions and Preparation ........................................... 5

9. Prepare and Install Burner/Control Box and

Combustion Chamber Tube ......................................................... 6-8

10. Install the Heat Exchanger Tube(s), Tail Pipe

Tube, and Turbulator Strip ....................................................... 8-11

11. Install Reflectors (including Standard Reflectors, Optional

Side Shield, and Optional Reflector Gap and End Covers) ..... 1 2

REFERENCES: Operation/Maintenance/Service Manual, Form RZ-NA-O-TR

Suspension Dimensions and Configuration Drawings Booklet, Form RZ-NA 607 Replacement Parts Manual, Form RZ-NAP-VR/TRP/TR

12. Venting ........................................................................................ 13-17

13. Combustion Air ................................................................................ 17

14. Gas Piping and Pressures .......................................................... 17-19

15. Electrical Supply and Connections .......................................... 19-20

16. Check Installation and Start-Up ..................................................... 2 1

OPTIONAL EQUIPMENT - Field Installed ................................ 22-23

17. Optional Heat Exchanger Tubes ("U", "L", 5-ft) ......................... 22

18. Hanger Kit, Option CK11 ............................................................... 22

19. Turnbuckle Kit, Options CK12-18 ................................................ 22

20. Combustion Air Inlet Kit, Option DE2 ......................................... 2 3

21. Dual Vent Kit, Option CC5 ............................................................. 23

22. Optional Side Shield, Options CD13-20 ....................................... 23

23. Optional Reflector Gap and End and Gap Covers ...................... 2 3

24. Multiple Heater Control, Options CL31 and 32 .......................... 23

25. Optional Unit-Mounted Thermostat Bracket Kit,

Option CM3 ................................................................................... 23

Index......................................................................................................... 24

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Don't touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury or death. Read the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment.

WARNING: Gas-fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances. See Hazard Levels, Page 2.

GENERAL

Installation should be done by a qualified agency in accordance with the instructions in this manual and in compliance with all codes and requirements of authorities having jurisdiction. The instructions in this manual apply to the heater models shown below .

Model Characteristics TR Indoor, Gas-Fired,

Low-Intensity Infrared Tubular System, 0-2000 ft (0-610M) elevation

TR-H Indoor, Gas-Fired,

Low-Intensity Infrared Tubular System, for 2001-8000 ft (611-2438M) elevation

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 1

Page 2

HAZARD INTENSITY LEVELS

1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage.

2. WARNING: Failure to comply could result in severe personal injury or death and/or property dam-

age.

3. CAUTION: Failure to comply could result in minor personal injury and/or property damage.

1A. Installation Codes

These units must be installed in accordance with local building codes. In the absence of local codes, in the United States, the unit must be installed in accordance with the National Fuel Gas Code ANSI Z223.1a (latest edition). A Canadian installation must be in accordance with the CAN/CGA B149.1 and B149.2 Installation Code for Gas Burning Appliances and Equipment. These codes are available from CSA Information Services, 1-800-463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements.

All electrical wiring must be in accordance with the National Electric Code ANSI/NFPA NO. 70 (latest edition) or, in Canada, the Canadian Electrical Code, part I-C.S.A. Standard C22.1.

The installing contractor must be familiar with all of the various requirements and is responsible for installing this heater in compliance with the applicable codes.

Special Installations --

Aircraft Hangars: In the United States, the heaters must be installed in accordance with ANSI NFPA 409 (latest edition), Chapter 5. NFP A Publications are available from the National Fire Protection Association, Batterymarch Park, Quincy , MA 02269. In Canada, installation in an aircraft hangar must comply with CAN/CGA-B149.2, Section

4.21. Both ANSI NFPA 409 and the CAN/CGA-B149.2 specify that the heater shall not be located in an area of an aircraft hangar where it may be subjected to physical damage by aircraft, cranes, moveable scaffolding, or other objects.

NFP A 409 specifies a c learance of 10 feet to the bottom of the heater from the highest surface of the wings or engine enclosures of the highest aircraft which may be housed in the hangar. CAN/CGA B149.2 specifies that an infrared heater installed in an aircraft hangar be at least 10 ft (3m) above either the highest fuel storage compartment or the highest engine enclosure of the highest aircraft which may occupy the hangar. NFPA 409 and CAN/CGA B149.2 specify a minimum clearance of eight feet from the floor to the heater in other sections, such as offices, or shops, that communicate with the aircraft hangar .

Public Garages: In the United States, heaters installed in public garages must be in accordance with National Fire Protection Association (NFP A) 88B (latest edition), Section 3-2.3. Overhead heaters must be located not less than eight feet above the floor and installed in accordance with the conditions of their approval. NFPA 88B requires the

following warning:

W ARNING: Minimum clearance marked on the heater must be maintained from vehicles parked under the heater .

In Canada, in a garage, the minimum clearance from the bottom of an infrared heater to the upper surface of the highest vehicle which may be housed therein shall be 50 percent greater than the certified clearance, and in no case less than eight feet (2.4m).

W ARNING: These tubular radiant heaters DO NOT qualify f or explosion-proof installations.

WARNING: The installing contractor must be certain that the area where the heater is being installed does not contain corrosive or toxic fumes or that elements in the atmosphere do not produce corrosive or toxic fumes in the presence of an open flame.

The chlorine atmosphere in enclosed swimming pool areas may cause burner and tube corrosion if the area is not ventilated. ASHRAE design guides suggest a minimum of 5-6 air changes per hour. The manufacturer recommends outside combustion air . T o pro vide outside combustion air , Option DE2, Combustion Air Inlet Kit, must be used.

1B. Warranty

Refer to limited warranty information on the warranty sheet in the "Owner's Envelope".

2. Description/General

These radiant tubular heaters are low-intensity infrared heaters using a power burner that fires into a 4" diameter steel tube, either 20, 30, 40, 50, 60, or 70 feet in length. The power burner is equipped with a blower for supplying combustion air and a spark-to-pilot-to-main burner ignition system. The highly emissive tubes are in 10-foot sections, and each section has a polished reflector. The tube section attached to the burner is the combustion chamber and all other sections are heat exchanger tubes with the exhaust end heat exchanger tube being identified as the tail pipe. Optional "L"-shaped, "U"-shaped, and 5-foot heat exchanger tubes are available to change the heater configuration to adapt to various applications.

Standard model heaters are designed to operate at full input rates of 50,000, 75,000, 100,000, 125,000, 150,000, 175,000, or 200,000 BTUH at altitudes from 0 to 2000 ft elevation. High altitude model heaters are designed to operate at full input rates of 50,000, 75,000, 100,000, 125,000, 150,000, 175,000, or 200,000 BTUH at altitudes from 2001 to 6000 ft elevation and from 6001 to 8000 ft at full input rates from 50,000 to 175,000 BTUH.

Venting may be either vertical or horizontal. A vent cap must be used. Install a vent cap supplied as Option CC1 or a fully-comparable, fieldsupplied vent terminal cap such as a T ype L Breidert Air-x-hauster®. (Type L Air-x-hauster® is a trademark of The G. C. Breidert Company.) Dual venting of two units is permissible when using an Optional Dual Vent Kit (Option CC5). These heaters are also approved for operation without outdoor venting.

Combustion air can either come from the heated space or be piped from outside. Outside combustion air should be supplied (1) if the building atmosphere has negative pressure; (2) if the building atmosphere is dirty or dusty; (3) if the building atmosphere contains substances that will cause toxic gas when combined with flame or flue products; or (4) if the heater is being installed in a tightly closed room that does not provide required air for combustion. Installation of an Optional Combustion Air Inlet Kit is required to provide outside combustion air .

Form RZ-NA-I-TR, Page 2

3. Specifications

Page 3

BTUH/Length/Configurations

Depending on the length and size of the heater, the heat exchanger sections may be installed in various configurations. Optional "L"-

BTUH I nput M inimum Length Maxim um Length

50,000 20 feet 30 feet

75,000 20 feet 40 feet 100,000 30 feet 50 feet 125,000 40 feet 50 feet 150,000 50 feet 60 feet 175,000 50 feet 70 feet

propane gas. Sizes 175-200 are available for use with natural gas only . The

BTUH Gas Supply Pressure

Input Type Minimum Maximum

50,000 - 150,000 Natural 4.5" w.c. 14" w.c.

175,000 - 200,000 Natural 6" w.c. 14" w.c.

50,000 - 150,000 Propane 11" w.c. 14" w.c.

supply pressure listed is the gas pressure required at the gas valve inlet. Measure gas pressure with a manometer.

Electrical Characteristics

200,000 50 feet 70 feet

shaped, 5-foot, and "U"-shaped heat exchanger tubes are available to adapt the heaters to these configurations (Option UC2 for "L"; Option UB3 for "U"; Option UA1 for 5-foot heat exchanger tube). Refer to the Suspension Dimensions and Configuration Drawings Booklet (in the Owner's Envelope) to determine the permissible configurations for each size and length of heater and guidelines for using the 5-ft heat exchanger tube.

Gas Type and Supply Gas Pressure

Voltage/Phase

Frequency Maximum Amps Flame Safety Pilot Burner Ignition Main Burner Ignition

Standard 115/1; Optional 208/1, 230/1, 460/1 60 Hertz

3.0 Electronic Spark Pilot

Sizes 50-150 heaters are available for use with either natural or

4. Clearances to Combustibles

Required clearances depend on the size of the heater (BTUH input), the position of the reflector, and the addition of an optional side shield on the rear side of the heater. Refer to illustrations in Figure 1 to def ine clearances.

Clearances to Combustibles

BTUH

Input (000)

inches

50/75/

100

125/

inches 78

150

175/

inches 84

200

BTUH

Input (000)

inches

50/75/

100

125/

inches 42 42 66 32 42 12

150

175/

inches 54 54 78 36 54 12

200 * If the heater is not vented to the outside of the building, the top clearance to combustibles is 18" (457mm). ** Refer to Paragraph 10 for side shield installation.

Below

66 12 24 36 24 6

1676 305 610 914 610 152

1981

2134 305 762 1219 610 152

0-30

Front

30 30 48 18 36 12

762 762 1219 457 914 305

1067 1067 1676 813 1067 305

1372 1372 1981 914 1372 305

Horizontal Clearances

Burner

Top*

End

30 48

305

762 1219

30 48

With Reflector Positioned

Front Rear Front

Rear

Heat

Exch anger

Bend (U o r L )

31-45

Exhaust

End

24 6

610 152

24 6

0-30o wit h Si de Sh i e l d

Vent

Rear

Front

Reflector

Top of Reflector

Below the Reflector

or Below the Tube

HORIZONTAL REFLECTOR

Burner

End

Exhaust End

Rear

Reflector

Optional Side Shield

HORIZONTAL CLEARANCES

Figure 1 - Clearance Orientation

Front

Reflector

Top of Reflector

Rear

Reflector

Below the Tube

REFLECTOR ANGLED (1° TO 45°)

Heat

Exchanger

Bend

Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90°F above the surrounding ambient temperature is not exceeded. The clearances listed in the tables are installation requirements. In addition, ANSI Z-223-1, Section 6.18, requires that signs be posted specifying the maximum permissible stacking heights to assure that the required clearances from the heater to combustibles are maintained in areas where items are stored under the heater.

Refer to Paragraph 1, Special Installations, for specific clearance requirements for heaters installed in aircraft hangars and public garages.

5. Location and Mounting Height

When selecting the installation location, major factors to consider are (1) Personal and Property Safety, (2) Personal Comfort, and (3) Heating Efficiency

(1) Safety

The location must meet the Installation Codes listed in Paragraph 1 and any local codes. These heaters are approved for indoor commercial/industrial installations only. Do not install these tubular radiant heaters in areas that contain corrosive or toxic fumes or where elements in the atmosphere could produce corrosive or toxic fumes in the presence of an open flame. These heaters do not qualify for explosion-proof installations.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 3

Page 4

5. Location and Mounting Height (cont'd)

Clearance to combustibles must be observed (See Paragraph 4), including clearances to stock that might be periodically stacked underneath the heater.

The supporting structure must have a load-carrying capacity of at least 200 lbs.

Do not locate the heater above or too close to electric lines, gas pipes, emergency sprinkler systems, or any such structures that could be adversely affected by radiant or convection heat.

Do not locate the heater where it could be damaged by high lifts, cranes, or any other such equipment.

Since chain suspension is required to allow for expansion and contraction of the tubes, proper positioning near large door openings is important. If the heater is being installed near a large door (ex: garage, loading dock, aircraft hangar, etc.), position the heater so that it will not "swing" in the wind. Lateral movement of the tubular system should be limited.

(2) Comfort

Because of the unique heat transfer features of an infrared heater, the comfort quality of the heat is greatly affected by the location of the heater. Rays of heat are emitted from the surface of the tubes and directed by the reflectors. When radiant heat rays reach a surface, those rays are absorbed, raising the temperature of that "object". Since infrared heat does not heat the air, a comfort advantage is that stratification does not occur. When the rays are not obstructed from reaching the floor, the floor and lower level areas maintain a more comfortable temperature than with convection (warm air) heating equipment.

For optimum comfort when infrared heaters are being used to "heat" personnel (spot heating), it is recommended that (1) the rays of heat be directed toward the person(s) from an angle rather than from directly overhead, and (2) the heater(s) be arranged so that rays are directed against at least two sides (or front and back) of the person(s). If the heater must be hung directly overhead, a higher mounting height will increase the comfort level because the greater distance will decrease the intensity level of the rays. Another significant factor when locating

the heater in relation to people is that the heat emitted from the burner/combustion chamber end of the tubular infrared heater is more intense than the heat emitted from the exhaust end. For this reason, a U-tube configuration is often best suited for overhead spot heat applications.

Tubular radiant heaters are engineered to provide comfort-level personal spot and space heating, but each application should be designed individually to determine the best, quality-comfort locations.

(3) Efficiency

Because of the unique features of radiant heat transfer, selecting the most efficient location for infrared equipment depends on the "floor" coverage of the emitted heat rays. Floor coverage distance can be figured as approximately two times the mounting height of the unit. However , comfort level heating depends on the infrared intensity , and intensity levels decrease with higher mounting heights and greater floor coverage. For more accurate measurement, consult the manufacturer's flux density tables.

For space heating infrared applications, the location of the units must be evaluated as part of the heater size selection. Determine the total BTU's required, the floor coverage required, and the mounting height. From this information design a heater size and location plan that will provide the most complete floor coverage without excessive overlapping. In most cases, perimeter heaters should be located parallel to the wall. The distance from the wall is determined by whether the reflectors will be angled or horizontal.

For spot heating applications, the tubular system should be located to direct the rays toward the area requiring heat. Depending on the installation, this can be done from directly overhead or reflector angled from the side. U-tube configurations are often best suited to overhead spot

Form RZ-NA-I-TR, Page 4

heating applications. Refer to the recommended minimum mounting heights below . Use the mounting height, the size of the heater, the heater conf iguration, and the application conditions to determine the most efficient location of the heater.

Recommended Minimum Mounting Height

R e flec tor Size (000 B TUH Input)

Position 50 75 100 125 150 175 200

11 12 13 15 16 17 18

Horizontal

30° Angle

45° Angle

feet

3.4 3.7 4.0 4.6 4.9 5.2 5.5

9 101113141516

feet

M 2.7 3.0 3.4 4.0 4.3 4.6 4.9

8 9 10 11 13 14 15

feet

2.4 2.7 3.0 3.4 4.0 4.3 4.6

6. Uncrating/Packaging

Check for shipping damage. If any damage is found,document the damage with the shipping agency and immediately contact your Reznor Dsitributor.

Because of their modular design, these heaters are packaged in sections and require field assembly . The burner/control box is in one carton, and the tubes are packaged in one, two or three cartons depending on the length of the system.

Burner/Control Box Carton - For the convenience of both the stocking and the non-stocking distributor, the burner/control boxes have two different packaging methods. Read carefully to determine whether or not

the burner/control box requires field conversion before being installed. (1) Burner/Control Box Packages

Package Contents TR50 Factory-assembled Size 50,000 BTUH heater TR75/100 Factory-assembled Size 75,000 BTUH heater

Conversion kit to change to a Size 100,000 BTUH heater

TR125/150 Factory-assembled Size 125,000 BTUH heater Conversion kit to change to a Size 150,000 BTUH heater

TR175/200 Factory-assembled Size 175,000 BTUH heater Conversion kit to change to a Size 200,000 BTUH heater

(2) Burner/Control Box Factory Built to a Specific Size - If the burner/ control box carton does not have a label about field conversion, the carton contains a burner/control box factory-built to a specific size. Check the rating plate to verify size and type of gas.

Tube Cartons - Tubes are also packaged so that a minimum number of cartons will cover all lengths of heater systems. This package identification system applies to all heaters, whether shipped from distributor stock or shipped to order from the factory . Before beginning installation, verify that the packages at the job site match the length of heater being installed.

Packaging Scheme for Tubes Pkg P/N Contents 120294 Combustion Chamber Tube; T ail Pipe with T urbulator 120295 Combustion Chamber Tube; Heat Exchanger T ube;

Tail Pipe with Turb ulator

120296 Heat Exchanger Tube; Heat Exchanger T ube with Turbula tor

Tube Packages (left) Required by Length of System Length Qty Pkg Qty Pkg

20 ft system requires 1 P/N 120294 30 ft system requires 1 P/N 120295 40 ft system requires 1 P/N 120294 1 P/N 120296 50 ft system requires 1 P/N 120295 1 P/N 120296 60 ft system requires 1 P/N 120294 2 P/N 120296 70 ft system requires 1 P/N 120295 2 P/N 120296

Reflectors, reflector brackets, and hardware packages are included in

Page 5

each carton. (NOTE: Chain for hanging is not included. Use either an Optional Hanger Kit and/or Turnbuckle Kit or field-supplied hardware. See suspension requirements in Paragraph 7.)

Accessory Cartons -- All field-installed options are shipped in separate cartons.

7. High Altitude Operation

All factory-built Model TR-H units are designed to operate at full input rates at elevations from 2001 to 6000 ft (611-1830M). In addition, Model TRH in Sizes 50 to 175 will operate at full rate at elevations from 2001 to 8000 ft (611-2440M).

High altitude kits are available to convert Size 50, 75, 100, 175, and 200 sea level burner/control boxes for use at high altitudes. Kits are available for all sizes to convert from one high altitude le vel to another .

If the heater being installed requires high altitude conversion, contact your distributor to obtain the appropriate kit and complete the conversion as part of the burner/control box preparation in Paragraph 9.

High Altitude Conversion Kits

Gas feet meters

Natural

Propane

*Kits for Size s 125 and 150 may only be used to change a Model TR -H from one high altitude elevation to another. DO NOT attempt to field convert a sea level Model TR125 or TR150 to high altitude. **Canadian high altitude installations must choose kits designed for 2001-4000 ft (610-12 19M) elevation.

2001-4000 610-1219 U.S. or Canada** 126440 120880 120882 132664 132667 132670 132673

Gas

4001-6000 1220-1828 U.S. Only 126442 120884 120886 132682 132685 132688 132691

Only

6001-8000 1829-2438 U.S. Only 126444 120888 120890 132700 132703 132706 N/A 2001-4000 610-1219 U.S. or Canada** 126441 120881 120883 132676 13 2679 N/A N/A

Gas

4001-6000 1220-1828 U.S. Only 126443 120885 120887 132694 132697 N/A N/A

Only

6001-8000 1829-2438 U.S. Only 126445 120889 120891 132712 132715 N/A N/A

(full rate operation)

8. Suspension Dimensions and Preparation

Refer to the Suspension Point Dimensions and Installation Configuration Drawings Booklet. This booklet provides suspension point dimensions, illustrations of permissible configurations for each size and length of heater, and requirements that must be met to include an optional 5-ft heat exchanger tube in the system. From the dimensions on the selected configuration drawing, determine the building suspension points.

WARNING: Install heaters only in the configurations illustrated or noted in the configuration booklet (Form RZ 607 in the Owner's Envelope). Don't install a heater in a configuration that is not permissible for that BTUH input capacity or length. See Paragraph 3 and Hazard Levels on page 2.

Suspension Point Requirements:

1) Supporting structure must have a minimum load-carrying capacity of 200 lbs. (Do not suspend the heater from gas piping or electrical conduit.)

2) Clearances to combustibles must be observed. See Paragraph

3) Heater must be suspended by hanging chains. Chain, "S" hooks, and/or turnbuckle length at each suspension point must be a minimum of 12 inches. All chains suspending tubes must be plumb. See Figure 2 for dimensions for burner/control box suspension points.

4) Refer to Paragraph 5 for recommended minimum mounting heights. The installer is responsible for properly and adequately

fastening the chains to the building and supporting the weight of the heater. Depending on the type of building construction at the installation site, either attach the chain support directly to the building or attach and extend a support to the location needed. SUPERSTRUT® brackets or a comparable metal strut material is well suited as a support structure that requires numerous suspension points.



 Chain must accept a 1/4" "S" hook and have a minimum of 200



lbs working load rating. Use either optional hanging chain kit (Option CK11) or field-supplied chain.

TR/TR-H TR-H only

50 75 100 125* 150* 175 200



 Since the heater must be level, turnbuckles are recommended at the "S"



hook connections on the heater. Turnb uckles must be of steel or malleable iron. Use either optional turnbuckle kits (Options CK12-20) or field-supplied equivalent.



 A minimum length of 12" of chain, "S" hooks and/or turnbuckle is required



at each suspension point.



 Chains suspending tubes must be plumb when the heater is installed.

 

 Suspension points required for the burner/control box are illustrated in



Figure 2.

This tubular radiant heater must be suspended with chain because the tubes will expand when heated. The overall length of a straight system will expand approximately as shown in the table.

TR/TR-H

Straight System Expansion Length

70 ft 2-3/4" (70mm) 60 ft 2-3/8" (60mm) 50 ft 2-1/8" (54mm) 40 ft 1-7/8" (48mm) 30 ft 1-1/2" (38mm) 20 ft 1-1/8" (29mm)

Figure 2 - Suspension Dimensions and Hanging Arrangement of the

installer or part of the building structure

Burner/Control Box

A + A/4

Optional turnbuckle

Use for convenience

if space permits.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Structural support added by the

At least 12 (305mm) of chain MUST BE used for proper expansion movement.

Page 5

Page 6

9. Prepare and Install Burner/Control Box and Combustion Chamber

Model Size is stamped in the upper left hand corner

Combustion Air Restrictor Plate

10-32 Nuts

Rubber tubing (attaches to combustion airflow sensor)

Combustion Airflow Sensor

Tube

There are very important steps that must be followed to prepare, suspend, and assemble these tubular radiant heaters. Preparing the heater, suspension, and field assembly are the responsibility of the installer. Follow all instructions carefully .

STEP 1) Prepare Burner/Control Box

All burner/control boxes require some field preparation. The type of preparation depends on how the unit was ordered and where it will be installed. Determine which of these six situations matches your application and follow the appropriate instructions. The first three are for units ordered by specific size; the last three are for burner/control box packages that cover two sizes. (Refer to Paragraph 6 for further explanation on packaging.)

• The unit was ordered as a specific size to be installed at a specific

elevation (sea level or high altitude) and is being installed at that elevation. Proceed to STEP 2 of these Preparation instructions.

• The unit was ordered as a specific size to be installed at sea level

to 2000 ft and is being installed above 2000 ft (NOTE: Does not

apply to Sizes 125 and 150). Install the high altitude kit selected in Paragraph 7. Follow the instructions provided with the kit. When the kit is installed, proceed to STEP 2 of these Preparation Instructions.

• The unit was ordered as a specific size to be installed at an

elevation above 2000 ft and is being installed at a different elevation above 2000 ft. Install the high altitude kit selected in Paragraph

7. Follow the instructions provided with the kit. When the kit is installed, proceed to STEP 2 of these Preparation Instructions.

• The burner/control box was ordered as a TR75/100, TR125/

150, or TR175/200 and will be installed at sea level to 2000 ft as a Size 75, 125, or 175. Proceed to STEP 2 of these Preparation

instructions. (The Size Conversion Kit shipped with the burner/control box will not be used.)

• The burner/control box was ordered as a TR75/100 or TR175/

200 and will be installed above 2000 ft elevation as a Size 75, 100, 175, or 200. Install the high altitude kit selected in Paragraph 7.

Follow the instructions provided with the kit. When the kit is installed, proceed to STEP 2 of these Preparation Instructions. (The Size Conversion Kit shipped with the burner/control box will not be used.)

• The burner/control box was ordered as a TR75/100, TR125/

150, or TR 175/200 and will be installed at sea level to 2000 ft elevation as a Size 100, 150, or 200. Follow the instructions below

to install the size conversion kit shipped with the burner/control box.

Instructions to Change the Combustion Air Restrictor Plate and Burner Orifice to Field Convert a Burner/Control Box from Size 75,000 to 100,000; or from Size 125,000 to 150,000; or from Size 175,000 to 200,000. Parts Required: Conversion package in the burner/control box includ-

ing a burner orifice, a combustion air restrictor plate, and conversion labels.

1. Conversion Size Labels (one on the restrictor plate, one or two

loose) -- Fill-in all labels stating that the burner/control box has been converted to either a Size 100,000, 150,000 or 200,000.

2. Change Air Restrictor Plate -- Refer to Figure 3A and identify the

combustion air inlet on the side of the burner box. Locate the paper warning label on the factory-installed combustion air restrictor plate. Attached to the restrictor plate is a combustion air sensor tube and bracket. See Figure 3B.

Remove the hardware (screws and/or nuts) holding the combustion

air sensor bracket and the restrictor plate. Remove and discard the factory-installed combustion air restrictor plate. Using the same hardware, attach the combustion air restrictor plate shipped in the parts bag. Re-attach the combustion air flow sensor bracket.

Form RZ-NA-I-TR, Page 6

Figure 3A - Combustion Air Inlet Side of

Burner/Control Box

Combustion Air Restrictor Plate

IMPORTANT

Tubing to Pressure Switch

Warning label which must be removed

Static Pressure Port

Combustion Airflow Sensor

Figure 3B - Remove factory-installed air restrictor plate and replace with the restrictor plate in the parts bag

3. Change Burner Orifice - Open the hinged access panel on the

bottom of the burner/control box. Locate the burner orifice. See Figure 4. Using a 9/16" open-end wrench, remove and discard the factory-installed burner orifice. Install the burner orifice shipped in the parts bag. Close the bottom panel.

Figure 4 - Burner/Control Box Showing Location of the Burner Orifice

Burner Orifice

-- Remove with 9/16" open end

wrench

Page 7

4. Adhere label(s) to the burner/control box directly below the rating

plate.

Field size conversion is complete. Continue to STEP 2) Install Com-

bustion Air Inlet Cover. STEP 2 -- Install Combustion Air Inlet Cov er -- Applies to all burner/

control boxes. From the hardware bag in the burner/control box, remove the instruction

sheet and the parts listed in Figure 5.

Figure 5 - Combustion Air Inlet Cov er

Qty Description

1 Combustion Air

Inlet Cover

4 Screws, #10 x

1/2" long

Instructions:

1. Refer to Figure 6 and identify the combustion air inlet side of the burner box. If paper warning label is attached, remove.

Figure 6 - Combustion Air Inlet Side of the Burner/ Control Box

STEP 3 -- Assemble and Suspend the Burner/Control Box and Combustion Chamber Tube

Use these parts (from the hardware bag) to assemble the box and tube.

Qty Description P/N 4 Lockwashers 1333 4 Nuts 1035 1 Gasket 116029

Instructions:

1. Identify the Combustion Chamber Tube -- The tube with the

square flange welded to one end.

2. Attach Combustion Chamber Tube to Burner/Control Box --

Slide the gasket over the bolts on the burner end of the burner/control box (See Figure 8B). Position the tube so that the hangers (on the end of the tube) are toward the top and bottom. See Figure 8A.

Slide the flange over the bolts. See Figure 8B.

Figure 8A - End of Combustion Chamber T ube

Position hanger brackets at the top

and bottom Showing Position of Hanger Brackets

Use the washers and nuts to attach the combustion chamber flange securely to the burner/control box. (The bolts are pre-welded to the inside of the box.)

3. Suspend the Combustion Chamber Tube/Burner Box Assem-

Combustion Air Restrictor Plate

Warning label which

RTANT

Tubing to Pressure Switch

2. Position the combustion air inlet cover over the air inlet opening. Using the four screws in the parts bag, attach the cover to the burner/ control box. See Figure 7.

must be removed

Static Pressure Port

Combustion Airflow Sensor

Figure 7 - Attach Combustion Air Inlet Cover (Fieldattachment of the combustion air inlet cover is required with either an indoor or outdoor combustion air supply. )

Figure 8B - Attach the Combustion

Chamber T ube to the Bur ner/Control

Box. Alter nately tighten nuts. Burner/Control Box

Fiberglass Gasket

Combustion Chamber

Lock washers

5/16-16 Nuts (tighten alternately)

bly

Parts needed from the hardware bag: 3 "S" Hooks Attach the two "S" hooks to the hanger brackets on the burner/control

box. Attach the third to the top hanger bracket on the end of the combustion chamber tube. Suspend the assembly from the three hanging chains. Refer to Figure 9.

The illustration in Figure 9 includes turnbuckles. Tur nbuckles are

Attach

Attach "S" Hook

"S"

Hook

Figure 9 Suspended Burner/ Control Box with attached Combustion Chamber T ube

Attach "S" Hook

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 7

Page 8

9. Install Burner/Control Box and Combustion Chamber Tube (cont'd)

3. Suspend the Combustion Chamber Tube/Burner Box Assembly (cont'd)

recommended for use in leveling the heater. If turnbuckles are included in heater suspension, use only optional turnbuckles or field-supplied turnbuckles of steel or malleable iron.

4. Draw Bolts -- There are two 4-1/2" long bolts left in the hardware bag. These bolts are provided as an aid in connecting tubes. Keep the bolts and

follow the tube connection instructions in Paragraph 10.

10. Install the Heat Exchanger Tube(s), Tail Pipe Tube, and Turbulator Strip

There are very important steps that must be followed to suspend and assemble these tubular radiant heaters. Preparing the heater, suspension, and filed assembly are the responsibility of the installer. Follo w all instructions carefully. Throughout the instructions, continued reference to the installation configuration drawing is required.

1) Identify the Heat Exchanger and Tail Pipe Tubes and the Parts Packaged with them (Refer to the illustrations in Figures 10A-10E and

the configuration drawing in the configuration booklet):

Expanded

End

10' Straight Tube 5' Straight Tube

T w o Hanger Brackets

"U"

"L" T ube

Tube

"U" and "L" tube packages include field-assembled reflectors

Figure 10B - Tail Pipe Tube (10')

Expanded End

A parts bag is supplied with each heater tube and tail pipe. The bag contains hardware needed to connect two tubes, an "S" hook, and an instruction sheet.

Figure 10C Connection Hardware Parts Bag, P/N 116017

Figure 10E Reflector, Reflector Retainer , and

Retainer

Reflector Bracket and Hardware (Ubolt and nuts)

Bolts

Square Nuts

Figure 10A - Heat Exchanger T ubes (Straight, "U", and "L")

Swedged End with One

Hanger Bracket

Figure 10D - One Section of the Field-Installed T urbulator Strip

Clamping Rings

Lock W ashers

Reflector

Bracket

One 10' reflector and two reflector retainers and two brackets with hardware per 10' straight tube. Optional 5' heat exchanger tube includes a 5' reflector and two sets of retainers and brackets with hardware. Follow installation instructions in Paragraph 11.

2) Suspend and Connect the Heat Exchanger Tubes and Tail Pipe

-- Follow the Configuration Drawing Layout

Connect each tube as it is suspended. If your configuration requires a turbulator strip before a "U" or "L" tube, insert the turbulator strip before the "U" or "L" tube is connected. Follow the instructions in Step No. 3) on pages 9-11, and install two sections of turbulator strip. (This will only

Form RZ-NA-I-TR, Page 8

occur when installing a 40' to 70' system in a configuration where a "U" or "L" tube connects directly to the tail pipe.)

Suspending Straight (5-ft or 10-ft) Heat Exchanger Tubes and "U" T ubes - Attach an "S" hook to the hanger bracket and suspend the

tube from the next hanging chain. Slide the expanded end over the previous tube and make the connection.

Page 9

Installing "L" Heat Exchanger T ubes - "L" tubes do not require a suspension point. When the configuration requires an "L" tube, slide the expanded end over the previous tube and make the connection.

Suspending the T ail Pipe - Attach an "S" hook to the hanger bracket and suspend the tube from the last hanging chain. Slide the expanded end over the previous tube and make the connection.

Connecting the Tubes - Using the hardware in the bag packaged with each tube, follow the steps in Figure 11 to connect the tubes.

1) Connection Hardware

Square Nuts

Bolts

2) Step 1

Combustion

products flow

direction

Figure 11 - Steps for Connecting Tubes

Lock Washers

Suspended T ube Section

T ube Section to be added (suspend at opposite end)

Clamping Rings

3) Step 2

4) Connected Tubes

Tighten bolts securely.

IMPORT ANT: If tubes do not slide together easily, f ollow Installation Tip below .

Be certain inner tube mates to bottom of expansion in outer tube.

Installation Tip: If tubes are difficult to slide tubes together , use the two 4-1/2" long bolts from the b urner/contr ol box parts bag to draw the tubes together . F ollow illustrated Step 2 (Figure 11, page 9), using the 4-1/2" bolts. Alternate tightening the upper and lower bolts. When the tubes are in position, remove one of the long bolts, replace with a connecting bolt, and secure. Repeat, replacing the other bolt. Re-use the 4-1/2" bolts as needed.

3) Install the Turbulator Strip -- Locate turbulator strip sections.

System L ength 20 30 40 50 60 70

Tube Package(s) E F E G F G E G G F G G

Full Size Turbulator Section, 37-1/8" long Sma ll Turbulator Section, 26" long

333232322322

101000100000

Figure 12A - Turbulator Strip Section

Figure 12B - Interlock Sections as Turbulator Strip is

Instructions: Install a turbulator strip in a tube only after

that tube has been suspended and connected to the previous tube. Refer to Figures 12A and 12B. Install the turbulator strip by sliding a section into the tube, connecting the next section, and sliding the connected sections on into the tube(s). Follow the selected configuration drawing in the configuration booklet and the instructions in the chart on page 11.

Installed

Turbulators interlocked ready for insertion into heat exchanger

Slide Together

Turbulators

tubes.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 9

Page 10

10. Installing the System (cont'd)

Length

Strai

Tubes

20 ft

25 ft

30 ft

BTUH

Size

(000)

50 75

50 75 50 75 0 - 8000 ft*

Ele vation

0 - 8000 ft*

Configuration

(Must be illustrated in t he

Suspension Dimension and

Configuration Booklet.)

St ra igh t

"U" or "L"

All

Turbulator Sections

In Tube

Packages

Qty Size** Qty Size**

3 37-1/8" 1 26" 3 37-1/8" 1 26" 3 37-1/8"

3 37-1/8"

Configuration

3 37-1/8" 1 26" 3 37-1/8"

3 37-1/8"

100

35 ft

40 ft

45 ft

50 ft

0 - 8000 ft*

100

0 - 8000 ft*

100 125

100

0 - 8000 ft*

125

100 125

0 - 8000 ft*

150

175

0 - 2000 ft

200 175 2001-8000 ft*

All Str aight heat exchanger tube adjacent

to the tail pipe "U" or "L" tube adjacent to the tail

pipe

(See Figure 12D)

Str aight heat exchanger tube adjacent to the tail pipe "U" or "L" tube adjacent to t he tail pipe

(See Figure 12D)

Str aight heat exchanger tube adjacent to the tail pipe

"U" or "L" tube adjacent to t he tail pipe

(See Figure 12D)

All 5 37-1/8"

(See Figure 12C)

(Se e Figure 12C)

(See Figure 12C)

3 37-1/8"

5 37-1/8" 1 26" 5 37-1/8"

1 26" 3 long sections after tail

5 37-1/8" 1 26" 5 37-1/8"

1 26" 3 long sections after tail

5 37-1/8"

3 37-1/8"

5 37-1/8"

3 37-1/8"

200 2001-6000 ft*

55 ft

150 0 - 8000 ft*

175

0 - 2000 ft

200

175 2001-8000 ft*

Str aight heat exchanger tube adjacent to the tail pipe "U" or "L" tube adjacent to t he tail pipe

(See Figure 12D)

All 5 37-1/8"

(See Figure 12C)

5 37-1/8"

3 37-1/8"

200 2001-6000 ft*

150 0 - 8000 ft*

175 200

175 2001-8000 ft*

0 - 2000 ft

Str aight heat exchanger tube adjacent to the tail pipe "U" or "L" tube adjacent to the tail pipe

(See Figure 12D)

All 7 37-1/8"

(See Figure 12C)

7 37-1/8"

5 37-1/8"

3 37-1/8"

200 2001-6000 ft*

65 o r

70 ft

175

0 - 2000 ft

200

175 2001-8000 ft*

Str aight heat exchanger tube adjacent to the tail pipe

"U" or "L" tube adjacent to the tail pipe

(See Figure 12D)

All 7 37-1/8"

(Se e Figure 12C)

7 37-1/8"

5 37-1/8"

3 37-1/8"

200 2001-6000 ft* * To install a heater above 2000 ft elevation, that heater must either be factory-built for the required elevation or field-conver ted to that elevation. Check the rating plate or field conversion label for allowable altitude. ** Metric equivalent: 37-1/8" is 943mm; 26" is 660mm

Form RZ-NA-I-TR, Page 10

(Some sections may not be used; follow instr uctions.)

Used

in the

Quantity, Type and

WHEN to Instal l

All 4 sections after tail pipe is connected 3 long sections after tail pipe is connected

All 3 sections after tail pipe is connected

5 long sections after tail pipe is connected

2 long sections before "U" or "L" is con nected

pipe is connected 5 long sections after tail

pipe is connected 2 long sections before "U" or "L" is con nected

pipe is connected All 5 sections after tail

pipe is connected

2 sect ions before "U" Int o end of st raight or "L" is connected before "U" or "L" 3 sections after t ail pipe is connected

3 sections after t ail pipe is connected All 5 sections after tail pipe is connected 2 sections before "U" or "L" is connected 3 sections after t ail pipe is connected 3 sections after t ail pipe is connected 5 sections after tail pipe is connected 2 sect ions before "U" Int o end of st raight or "L" is connected before "U" or "L" 3 sections after t ail pipe is connected 3 sections after t ail pipe is connected 5 sections after tail pipe is connected 2 sect ions before "U" Int o end of st raight or "L" is connected before "U" or "L" 3 sections after t ail pipe is connected 3 sections after t ail pipe is connected

Into exhaust end of tail pipe Into exhaust end of tail pipe

Into exhaust end of tail pipe

Into end of straight tube before "U" or "L"

Into exhaust end of tail pipe

Into exhaust end of tail pipe Into end of straight tube before "U" or "L" Into exhaust end of tail pipe

Into exhaust end of tail pipe

Into exhaust end of tail pipe Into end of straight tube before "U" or "L" Into exhaust end of tail pipe Into exhaust end of tail pipe

Into exhaust end of tail pipe

Into exhaust end of tail pipe Into exhaust end of tail pipe

Into exhaust end of tail pipe

Into exhaust end of tail pipe Into exhaust end of tail pipe

WHERE to Inst all

Page 11

Figure 12C - Examples of Configurations with the Tail Pipe Adjacent to a Straight Heat Exchanger Tube

Tail Pipe

Tube

Tail Pipe

Straight

Tube

Straight

Tube

Figure 12D - Examples of Configurations that require more than three turbulator strips and have the tail pipe adjacent to an "L" or "U" heat exchanger tube

Tail Pipe

LTube

Straight

Tube

Straight

Tube

Tail Pipe

U

Tube

Tail Pipe

T o install turb ulator:

1) Attach the tail pipe to the straight pipe.

2) Insert a turbulator section into the tail pipe.

3) Interlock turbulator sections as they are inserted (See Figure 12B).

4) Continue until all required sections are in place.

T o install turb ulator:

1) Before attaching the "U" or "L" tube, insert two interlocked turbulator sections (See Figure 12B) into the last straight tube.

2) Attach the "U" or "L" heat exchanger tube to the straight tube.

3) Attach the tail pipe to the "U" or "L" tube.

4) Insert three interlocked turbulator sections into the tail pipe.

Su mmary of Number of Sections Required to "Build" Turbulator Strip

(NOTE : There may be sections in the packages that ar e not used.)

Elevation of

Installation (ft)

0 - 8000 50-75-100 30 ft 3

0 - 2000 175-200 50 ft 5

2001-8000 175-200* 3

0 - 8000 150 55, 60 ft 5 0 - 2000 175-200 55, 60, 5

2001-8000 175-200* 65, 70 ft 3

*Size 200 - Maximum elevation is 6000 feet.

BTUH Sizes

(000)

50-75 20 ft "U" or "L" 3

75-100 35 ft Straight, 3

75-100-125 40 ft "U", 5

100-125 45 ft and 5

100-125-150 "L" 5

4) Level the System and Close "S" Hooks

Tubes must be lev el. Use a spirit level and adjust the turnb uckles or chain links. Close all "S" hooks being careful not to change the chain length. When the system is level, re-check to be sure that all bolts connecting the tubes are tightened securely .

Straight systems should be straight; systems with "L" tubes should be at right angles; and "U" shaped systems should be parallel.

Length

(Straight)

20 ft Straight 4 (3 long, 1 short)

25 ft 3

Configuration

No. of Sections used in

Turbulator Strip

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 11

Page 12

11. Install Reflectors (including Standard Reflectors, Optional Side Shield and Optional Reflector Gap and End Covers)

WARNING: Do not operate heater without reflectors. See Hazard Intensity Levels, page 2.

Packaged with each straight tube is a reflector, two reflector brackets with hardware, and two reflector retainers (Refer to Figure 10E on page 7). Follow the instructions to install a reflector on all straight tubes.

NOTE: If the installation includes an optional side shield, the side shield package (Options CD13-20) includes two additional reflector brackets and retainers for each 10-ft tube. All four br ackets must be attached to each 10-ft tube before installing the reflector.

Reflector Installation Instructions

1. From the table, determine the

number of brackets (and retainers) required per tube and select the appropriate illustration (Figure 13A or 13B).

2. Install Reflector Brackets

Tube

Length

Side

Shield

Number of

Brackets

Refer to

Figure

10-ft Without 2 13A 10-ft With 4 13B

5-ft Without 2 13A 5-ft With 2 13B

(See Figure 13A or 13B)

a) Slide the U-bolt over the tube at the determined location. b) Position the reflector bracket as illustrated (end flanges extend-

ing upward) and slide the bracket over the bolt ends. Adjust the bracket to the desired reflector angle (0-45

). Use the nuts to

attach the reflector bracket to the U-bolt.

c) Repeat the procedure to install all required brackets.

Figure 13A - Locations for Reflector Brackets for Systems without an Optional Side Shield

10-ft Heat Exchanger Tube

U-Bolt

Optional 5-ft Heat Exchanger Tube

12

(305mm)

Reflector Bracket

6 feet (1.8M)

36 (914mm)

12

(305mm)

approximate

3. Install the Reflector, Optional Side Shield, and Reflector

Retainers (Refer to Figure 15) a) All Installations -- Nestle the reflector inside the flanged edges

of the reflector brackets.

b) Installations with Optional

Side Shield -- The side shield is

modular with two sections per 10-ft tube. When side shields are included in the installation, drill a

Figure 14 - With optional side shield, insert a screw in each tube joint to prevent tubes from turning

9/64" hole in each tube joint and insert the screw provided (See Figure 14). Hang the side shield sections over the ends of the reflector brackets (Maximum angle with side shield is 30°). IMPOR-

TANT: Install side shield on one side of the system only.

U-bolt

1/2" (13mm)

Reflector

Drill 9/64" hole

Reflector Retainer

Optional

Side

Shield

Reflector Bracket

Figure 15 - Install Reflector ,

Side Shield (Optional), and

Reflector Retainers

Form RZ-NA-I-TR, Page 12

Figure 13B - Locations for Reflector Brackets for Systems with an Optional Side Shield

10-ft Heat Exchanger Tube

2 ft

(610mm)

13

(330mm)

Optional 5-ft Heat Exchanger Tube

32-3/4

(832mm)

c) All Installations -- Position a wire retainer over the reflector and hook the

ends through the holes in the reflector brackets. Install a retainer at each reflector bracket.

d) All Installations -- Repeat the instructions to install reflectors on each

straight section of tube in the system. Do not operate the heater without all

reflectors installed.

4. Install Optional Reflector Gap Covers -- The optional gap covers are

designed to provide the infrared tubular system with a continuous reflector while still allowing for system expansion. If optional reflector gap covers are included in the installation, follow the illustrated instructions included in the option package. Reflectors on systems with gap covers cannot be rotated.

5. Install Optional Reflector End Cover -

- The optional end covers are designed to "close" the vertical space on both the combustion chamber end and the tail pipe end of the reflector length. The end covers may only be installed on units that have optional reflector gap covers. Follow the illustrated instructions included in the option package.

6. Rotating Reflectors -- Reflectors on straight systems without reflector gap

covers or a side shield may be angled up to 45° by rotating the U-bolt and

reflector bracket. Reflectors with gap covers cannot be rotated. Reflectors on straight systems with a side shield may be angled up to 30°. The side shield must hang vertically .

13

(330mm)

24-1/2

(622mm)

(832mm)

32-3/4

(832mm)

Figure 16A Optional Reflector Gap Cover

Figure

16B Optional Reflector

End

Covers

Page 13

If the system includes a "U" or "L" heat exchanger tube, the reflectors on either adjacent side of the "U" or "L" reflector cannot be rotated and must remain horizontal. All reflectors in a section or leg of the tubular system should be at the same angle.

12. Venting

V enting must be in accordance with the National Fuel Gas Code Z223.1 (NFP A

54) or CAN/CGA B149.1 and B149.2, Installation Code for Gas Burning Appliances and Equipment, and all local codes. ANSI standard applicable to this heater does not require venting categorization; if such a requirement existed, this heater would be in Category III. (Category III appliances have a positive-pressure vent requiring a gastight sealed vent system.) These tubular infrared heaters have been designed to operate safely and efficiently with vent pipe lengths sho wn in the Vent Length T able. Vent systems may either be vertical or horizontal. The type of vent required depends on the size of heater and the vent run configuration.

Type of Vent Required by Vent Category

Model Sizes 50-125 150-200

- with a Horizontal Vent Run Category III Category III

- with a Vent Run that is at least one-half Category I vertical (using equivalent lengths from the or Category III Vent Length Table below) Category III

- with a Dual Vent Adapter (Option CC5) Category III Category III

V ent terminal end may be either single-wall pipe or double-wall pipe . A vent terminal cap is required. Install a vent cap supplied as Option CC1 or a fullycomparable, field-supplied vent terminal cap such as a T ype L Breidert Air-xhauster®. (T ype L Air-x-hauster® is a trademark of The G. C. Breidert Company.) Dual v enting of two units is permissible when using an Optional Dual Vent Kit (Option CC5). Comply with the specific requirements and instructions in the following paragraphs.

Specific V ent Requirements

1. Vent Pipe Length - The vent lengths sho wn in the V ent T able are based on (1) the maximum permissible resistance to flow at which each model size will operate and (2) the potential for continuous condensing. Condensing in the vent pipe should not occur after equilibrium has been reached when the surrounding ambient temperature is 60°F unless otherwise noted (See Requirement No. 6, Condensation).

Do not exceed maximum vent length. Minimum vent length is 5 feet. Use equivalents listed when calculating for elbows and optional dual vent

adapter (Option CC5).

Ven t Length T able for Tubula r Infra red H ea ters

Vent Length Equivalent Length for

Straight

Tube

Length

(ft)

Input Size (000)

50 20, 25, 30 4 20 5 6.1 1.5 3 0.9 1-1/2 0.5 3 0.9

20, 25 4 45 5 13.7 1.5 6 1.8 3 0.9 6 1.8

75 30, 35 4 35 5 10.7 1.5 5 1.5 2-1/2 0.8 5 1.5

40 4 20 5 6.1 1.5 3 0.9 1-1/2 0.5 3 0.9 30, 35 4 45 5 13.7 1.5 6 1.8 3 0.9 6 1.8

100 40, 45 4 35 5 10.7 1.5 5 1.5 2-1/2 0.8 5 1.5

50 4 20 5 6.1 1.5 3 0.9 1-1/2 0.5 3 0.9 125 40, 45, 50 4 60 5 18.3 1.5 12 3.7 6 1.8 12 3.7 150 50, 55, 60 4 60 5 18.3 1.5 12 3.7 6 1.8 12 3.7

50, 55, 60, 175

65, 70

50, 55, 60, 200

65, 70

Must be deducted from the total vent length of

Vent Diameter

feet M

(inches)

Max Min Max Min ft M ft M ft M

4 60 5 18.3 1.5 12 3.7 6 1.8 12 3.7

Elbow

each

90°

heater.

45°

Elbow

Dual Vent

Adapter

Box

2. Vent Pipe Type - Use only 4-inch diameter vent pipe. If the type of vent required is Category III (refer to table

above), use either a vent pipe approved for a Category III heater or appropriately sealed 26-gauge galvanized steel or equivalent singlewall pipe.

If the type of vent required is Category I (refer to table above), unsealed 26-gauge galvanized steel or equivalent single-wall pipe or double-wall (T ype B) vent pipe may be used.

3. Vent Pipe Joints - Vent system joints depend on the vent category and the type of pipe being used.

If installed as a Category III appliance and using single-wall vent pipe, join pipes with at least two non-corrosive screws per

vent pipe joint and seal all joints to prevent leakage of flue gases into the building. For sealing joints, the use of Alumin um or TEFLON® (trademark of DuPont Corporation) tape suitable for 550°F is recommended (required in California). Vent tape of this type is available from the heater manufacturer as P/N 98266.

If installed as a Category III appliance and using vent pipe specifically approved for Category III vent systems, follow

the pipe manufacturer's instructions for proper sealing.

If installed as a Category I appliance (allowed only for Sizes 50-125 when at least half of the total equivalent length of the vent system is vertical), use at least two non-corrosive screws per

vent pipe joint on single-wall pipe or follow the pipe manufacturer's instructions for joining double-wall pipe.

Attach Vent Pipe to Heater - The last heat exchanger section

(tail pipe) is designed to permit direct attachment of a vent pipe, either straight or elbow .

Attach metal vent pipe using three non-corrosive screws spaced equal distance apart. See Figures 17A and 17B.

Non-corrosive sheetmetal screws spaced approximately 120° apart

Suspended Tail Pipe

Figure 17A Attach Metal V ent Pipe to Tail Pipe

Single wall elbow or

Single wall straight pipe section

T ape joint with high temperatur e aluminum tape or seal with high temperature silicone rubber sealant.

Figure 17B - Seal

T ail Pipe and Vent

Pipe Joint

5. Vent System Support - Vent pipe support is especially impor-

tant with the tubular infrared system because of the added stress which may be caused by expansion and contraction of the overall system. Support lateral runs a minimum of every six feet using non-combustible material, such as steel strap or chain. Do not rely on the heater for support of either horizontal or vertical vent pipe.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 13

Page 14

11. Venting (cont'd)

6. Condensation - If single-wall vent pipe is exposed to cold air or run through unheated areas, it must be insulated. Where extreme conditions are anticipated, install a means of condensate disposal.

Vent Terminal and Vent Cap - The vent system must be terminated

with the type of vent cap approved for use with this heater. The vent terminal and vent cap must be the same diameter as the vent run. Use either an optional (Option CC1) vent cap or equiv alent such as a T ype L Breidert Air-x-hauster®. (Type L Air -x-hauster® is a trademark of The G. C. Breidert Company.) A different style vent cap could cause nuisance problems and/or unsafe conditions.

See the illustrations in Figures 18 and 19 for requirements of both vertical and horizontal vent termination. Using either single or double wall vent terminals is illustrated. Many local codes require the use of doublewall (T ype B) vent for the portion of vent pipe (terminal) on the outside of the building.

If double-wall pipe is used in the vent terminal, follow the instructions below to attach the vent cap and to connect the double-wall pipe to the single-wall vent system.

INSTRUCTIONS FOR DOUBLE WALL PIPE INSTALLATION: Material Required: Double wall (Type B) Vent Pipe (Note:

Use only one piece of double wall vent pipe.); a thimble designed for double wall pipe (if construction is combustible); six 3/4" long sheetmetal screws; the vent cap; and a tube of silicone sealant.

Instructions to attach VENT CAP to DOUBLE WALL (Type B) VENT TERMINAL

Look for the "flow" arrow on the vent pipe. Attach the vent ca p to the "exhaust" end of the double wall pipe.

1) Slide the vent cap inside the pipe.

2) Drill a hole through the pipe and the vent cap. (Hole should be

slightly smaller than the sheet metal screw being used.) Using a 3/4" long sheet metal screw , attach the cap to the pipe.

3) Repeat Step 2) drilling and inserting two additional screws evenly spaced (120° apart) around the pipe.

Instructions to connect the SINGLE WALL VENT system to a DOUBLE WALL (Type B) VENT TERMINAL:

1) Slide the single wall pipe inside the inner wall of the double-wall

terminal pipe.

2) Drill a hole through both walls of the double wall pipe and the single wall pipe. (Hole should be slightly smaller than the sheet metal screws being used .) Using a 3/4" long sheet metal screw , attach the two pieces of pipe. Do not overtighten.

3) Repeat Step 2) drilling and inserting two additional screws evenly spaced (120° apart) around the pipe.

4) T o seal the annular opening (the gap between the single and double wall pipe), run a large bead of silicone sealant in the opening. The bead of sealant must be large enough to seal the opening, but it is not necessary to fill the full volume of the annular area.

Figure 18A - Vertical Vent Terminal Arrangements (drawings are not proportional; read all information)

SINGLE WALL - Single wall vent run and single wall terminal end

6 ft

(1829mm)

minimum

Roof Flashing

Roof pitched

Parapet or adjoining building

from 0 to 45°

Vertical flue extension must be 6 (152mm) higher than anticipated snow depth but no less than 24 (610mm) above the roof. Vertical pipe extension must be insulated.

An approved clearance thimble for single-wall vent pipe is required when the flue piepe extends

h combustible maerial.

throu

DOUBLE WALL - Single wall vent run and double wall terminal end

6 ft

(1829mm)

minimum

Roof Flashing

6 (152mm)

Parapet or adjoining building

minimum

Follow the instructions above to join double wall and single wall pipe and to attach a vent cap to double wall pipe.

Vertical flue extension to be 6 (152mm) higher than anticipated snow depth but no less than 24 (610mm) above the roof. Vertical pipe extension must be insulated.

Roof pitched from 0 to 45°

Clearance to be as specified on Type B (double wall) vent pipe

Figure 18B - Vertical Vent Terminal/Air Intake Arrangements (dra wings are not proportional; read all information)

SINGLE WALL - Single wall vent run; single wall terminal end; and single wall fresh air intake

6 ft (1829mm) minimum

Vertical flue extension to be 6 (152mm) higher than anticipated snow depth but no less than 24 (610mm) above the roof.

Parapet or adjoining building

Vertical pipe extension must be insulated.

Roof pitched from 0 to 45°

An approved clearance

thimble for single wall

vent pipe is required

when the flue pipe extends

through combustible

mat

rial

Form RZ-NA-I-TR, Page 14

3 ft (914mm)

minimum

Roof Flashing

If the fresh air intake is within 10 feet (3M) of the flue extension, the flue extension must be at least 12 (305mm) higher than the fresh air intake.

Fresh air intake must be 6 (152mm) higher than anticipated snow depth.

DOUBLE WALL - Single wall vent run; double wall terminal end; and single wall fresh air intake

6 ft (1829mm) minimum

Vertical flue extension to be 6 (152mm) higher than anticipated snow depth but no less

Parapet or adjoining building

than 24 (610mm) above the roof. Vertical pipe extension must be insulated.

Roof pitched from 0 to 45°

6 (152mm)

minimum

Follow the instructions above to join double wall and single wall pipe and to attach a vent cap to double wall pipe.

3 ft (914mm)

minimum

Roof Flashing

Clearance to be as specified on Type B (double wall) vent pipe

If the fresh air intake is within 10 feet (3M) of the flue extension, the flue extension must be at least 12 (305mm) higher than the fresh air intake.

Fresh air intake must be 6 (152mm) higher than anticipated snow depth.

Page 15

Horizontal Vent Terminal Clearances (See Figure 19)

(

Air Inlet Terminal Clearance -- The bottom of the air inlet terminal shall be located not less than one foot (30 cm) above grade and at least 6 inches (15 cm) above anticipated snow depth.

The distance of termination of the horizontal vent from adjacent public walkways, adjacent buildings, openable windows, and building openings must be in accordance with local codes , or in the absence of local codes, must conform with the National Fuel Gas Code. More stringent local codes supersede all provisions in these instructions and in the National Fuel Gas Code. Minimum clearances for the horizontal vent terminal are shown in the table on the right.

NOTE: Maintain the required 18" clearance from the wall to the vent terminal cap for stability under wind conditions and to protect the building. Products of combustion can cause

discoloration of some building finishes and deterioration of masonry materials. Applying a clear silicone sealant that is normally used to protect concrete driveways can protect masonry materials. If discoloration is an esthetic problem, relocate the vent or install

Structure

Forced air inlet within 10 ft (3.1m) 3 ft (0.9m) above* Combustion air inlet of another appliance Door, window or gravity air inlet 4 ft (1.2m) horizontally (any building opening) 4 ft (1.2m) below

Electric meter, gas meter ** and reli ef equipment Gas regulator ** 3 ft (0.9m) Adjoining building or parapet 6 ft (1.8m) Grade (ground level) 7 ft (2.1m) above *This heater is approved for installation as illustrated in Figure 19B. **Do not terminate the vent directly above a gas meter or service regu lator.

Minimum Clearances for Vent Termination Location (all directions unless specified)

6 ft (1.8m)

3 ft (0.9m) above 4 ft (1.2m) horizontally

a vertical vent.

Figure 19A - Horizontal Vent Terminal Arrangements (drawings are not proportional; r ead all information) SINGLE WALL - Single wall vent run and single wall

terminal end

Approved clearance thimble is required when flue pipe extends through combustible material.

18

(457mm)

minimum

Roof or building overhang

3 ft (914mm)

minimum

6 ft (1829mm)

minimum

DOUBLE WALL - Single wall vent run and double wall terminal end

18 (457mm) minimum

Roof or building overhang

Follow the

instructions

on page 14

to join double

wall and single

wall pipe and

to attach a vent

Parapet or adjoining building

cap to double

wall pipe.

6 (152mm)

minimum

3 ft (914mm)

minimum

6 ft (1829mm)

minimum

Parapet or adjoining building

Wall

Pitch flue pipe down toward outlet 1/4 per foot for condensate drainage.

Note position of vent cap openings.

Clearance to be

as specified on

Type B (double

wall) vent pipe

Wall

Pitch flue pipe down toward outlet 1/4 per foot for condensate drainage.

Note position of vent cap openings.

Figure 19B - Horizontal Vent Terminal/Air Intake Arrangements (drawings ar e not proportional; read all information)

SINGLE WALL - Single wall vent run; single wall terminal end; and single wall fresh air intake

Approved

clearance

thimble is

required

when flue

pipe extends

through

combustible

material.

18 (457mm) minimum

Pitch flue pipe down toward outlet 1/4 per foot for condensate drainage.

Wall

18

(457mm)

minimum

229mm) maximum

9

Roof or building overhang

3 ft (914mm)

minimum

Note position of vent cap openings.

Fresh air intake cap

6 ft (1829mm)

minimum

DOUBLE WALL - Single wall vent run; double wall terminal end; and single wall fresh air intake

Follow the

instructions

on page 14

to join double

wall and single

Parapet or adjoining building

wall pipe and

to attach a vent

cap to double

wall pipe.

18 (457mm)

minimum

6 (152mm)

Clearance to be

as specified on

Type B (double

wall) vent pipe

minimum

Wall

Roof or building overhang

18

(457mm)

minimum

Pitch flue pipe down toward outlet 1/4 per foot for condensate drainage.

Fresh air intake cap

9 (229mm) maximum

3 ft (914mm)

minimum

6 ft (1829mm)

Note position of vent cap openings.

minimum

Parapet or adjoining building

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 15

Page 16

11. Venting (cont'd)

Vent T erminal Arrangements (cont'd)

WARNING: Dual venting of two heaters is permitted only when using the Dual Vent Kit, Option CC5. (Refer to Figures 20A and 20B.) No other manifolding of vent runs is permitted due to possible back pressure and recirculation of combustion products into the building. See Hazard Levels, page

Duel V enting -- By using the Dual

Vent Option Kit, Option CC5, two heaters may use the same vent terminal. No other dual venting arrangement is approved.

Follow the installation instructions and requirements included in the Option Kit. See Vent Te rminal Arrangements in Figures 20A and 20B.

Figure 20B - Horizontal Dual Vent T erminal Arrangement

Single wall outer dual vent pipe Single wall inner dual vent pipe

clearance to combustibles

Dual Vent

Adapter Box

Figure 20A - Vertical Dual V ent T erminal Arrangement

6 ft (1829mm)

minimum

Roof Flashing

Parapet or adjoining bulding

6 (152mm)

clearance to combustibles

Vent pipe from heater

6 (152mm)

Vertical extension must be 6 (152mm) higher than anticipated snow depth but not less than 24 (610mm) above the roof

Approved thimble required when the flue pipe extends through combustible materials.

Dual Vent

Adapter Box

Roof or building overhang

3 ft (914mm)

18 (457 mm)

minimum

Single wall outer dual vent pipe Single wall inner dual vent pipe

6 ft (1829mm)

maximum

Vent pipe from heater

Parapet or adjoining building

minimum

6 ft (1829mm)

minimum

Unvented Installation -- These tubular radiant heaters are approved for operation without an outdoor vent. Before installing a tubular infrared heater in the unvented mode, extreme care should be exercised in examining the building atmosphere and structure. Fresh air requirements

are 4 CFM/1000 BTUH for natural gas and 5 CFM/1000 BTUH for propane gas.

• Do not operate in the unvented mode when dust or dirt are present.

• Do not operate in the unvented mode in a building where contami-

nants are in the air that will produce a toxic gas when burned or exposed to high temperatures.

NOTE: If either of the above situations exist, it is recommended that a vented system with an optional combustion air inlet be installed.

• Do not operate in the unvented mode if there is any doubt about the

Form RZ-NA-I-TR, Page 16

Approved thimble required when the flue pipe

Wall

extends through combustible materials.

6 ft (1829mm)

maximum

Pitch flue pipe down toward outlet 1/4 inch per foot for condensate drainage.

quality of the insulation in the building. Unvented operation in a building that has an uninsulated roof or that may have uninsulated structural members partially exposed to the outdoors may result in condensation. The condensation may be severe enough to drip and/ or cause corrosion.

• Do not install in the unvented mode with outside combustion air

unless the inlet air cap is at or below the plane of the heater .

When installing a tubular infrared heater in the unvented mode, a vent cap must be used and must be installed inverted as illustrated in Figure

21. When a heater is operated without being vented to the outdoors, "TOP"

clearance to combustibles changes to 18 inches (See Paragraph 4).

Page 17

Figure 21 - Inv ert Terminal Cap on Indoor Vent

Attach 90° elbow to tail pipe using three noncorrosive sheetmetal screws spaced approximately 120° a part.

90° Elbow

Attach vent cap to 90°

elbow using three non-

corrosive sheetmetal

V ent Cap

approximately 120° a part.

13. Combustion Air

The burner is equipped with a centrifugal blower to provide combustion air. The air for combustion can come either from the heated space or be piped directly from the outside. Combustion air should be piped from the outside if (1) the pressure in the building is negative, (2) the atmosphere is dirt laden, (3) the atmosphere contains any substance that will cause toxic gas when passed through a flame, or (4) the heater is installed in a tightly closed room that does not provide required air for combustion. If drawing combustion air from the heated space, the screened combustion air opening on the burner box must be kept clean. Maintain a minimum 12" clearance from the combustion air inlet opening. If the heater is located in a tightly closed room and is not equipped with a combustion air inlet pipe, provision must be made to supply air for combustion to the room.

The requirements for combustion and ventilation air depend upon whether the unit is located in a confined or unconfined space. An "unconfined" space is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the aggregate input rating of all appliances installed in that space. Under all conditions, enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space. Do not install a unit in a confined space without providing wall openings leading to and from this space. Provide adequate openings near floor and ceiling for ventilation and air for combustion, as shown in Figure 22, depending on combustion air source as noted below.

Add total BTUH of all appliances in the confined space and divide by figures below for square inch free area size of each (top and bottom) opening.

Figure 22 - Confined Space: A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating.

1. Air from inside building -- openings 1 square inch free area per

1000 BTUH. Never less than 100 square inches free area for each opening. See (1) in Figure 22 above.

(3)

(1) (2)

Confined

Space

(1)

Suspended

Tail Pipe

screws spaced

(2)

2. Air from outside through duct -- openings 1 square inch free area per

2000 BTUH. See (2) in Figure 22 above.

3. Air direct from outside -- openings 1 square inch free area per 4000

BTUH. See (3) in Figure 22 above. NOTE: For further details on supplying combustion air to confined space, see National Fuel Gas Code Z223.1 (latest edition). If directly piped outside combustion air is required, the burner/control box is designed to accommodate attachment of a 4" diameter inlet air pipe. For outside combustion air, use optional inlet air kit, Option DE2. Follow the instructions included with the kit. The inlet air pipe should be 4" diameter pipe of a noncorroding material. The maximum length of the inlet air pipe must not exceed the length shown in the Comb ustion Air Inlet Length T a ble below . If the inlet air pipe passes through moisture-laden air , insulation or double wall tubing may be needed to prevent condensation on the outside of the pipe. Use the combustion air inlet cap supplied with the option kit. A different type of combustion air inlet cap could cause nuisance problems and/or unsafe operating conditions.

Maximum Length of Outside Combustion Air Inlet Pipe

Type of BTUH Heater Length Maximum Equivalent Length for

Inlet Pipe Size (Straight Tubes) Length 90

50 20/25/30

4" 100 30/35/40/45/50

Smooth 125 40/45/50

Wall 150 50/55/60

4" 75 20/25/30/3 5/40 N/A N/A

Corrugated 100 30/35/40/45/50

or 125 40/45/50

Flexible 150 50/55/60 N/A N/A

Assumes the use of three feet of flexible pipe at the combustion

air inlet on the burner/control box.

If the air inlet terminal is located adjacent to the exhaust terminal, the terminals must be separated by a minimum distance of three feet. The only exception is when the air inlet is located directly below the horizontal vent cap. The required clearance between an air inlet terminal located directly below the vent cap is 18 inches as illustrated in Figure 19B. See Figures 18B and 19B in Paragraph 12 for illustrations and clearance requirements of an air inlet terminal located adjacent to the heater vent terminal.

75 20/25/30/35/40 5 ft (1.5M)

175 50/55/60/65/70 200 50/55/60/65/70

50 20/25/30

175 50/55/60/65/70 200 50/55/60/65/70

80 ft

(24.3M)

60 ft

(18.3M)

40 ft

(12.2M)

30 ft

(9.1M)

Elbow 45o Elbow

10 ft (3M)

10 ft (3 M ) 5 ft (1.5M )

14. Gas Piping and Pressures

All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223.1a (latest edition) or CAN/CGA-B149.1 and B149.2, published by the Canadian Gas Association (See Paragraph 1). Gas supply piping installation should conform with good practice and with local codes.

Heaters for natural gas are orificed for operation with gas having a heating value of 1000 (± 50) BTUH per cubic ft. If the gas at the installation does not meet this specification, consult the factory for proper orificing.

The gas supply must have sufficient pressure to supply the burner plus any other gas-fired appliances. Gas Supply pressure required at the burner (measured with a manometer):

BTUH Gas Supply Pressure

Input Type Minimum Maximum

50,000 - 150,000 Natural 4.5" w.c. 14" w.c.

175,000 - 200,000 Natural 6" w.c. 14" w.c.

50,000 - 150,000 Propane 11" w.c. 14" w.c.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 17

Page 18

14. Gas Piping and Pressures (cont'd)

Sizing Gas Supply Lines

Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft)

Specific Gravity for Propane Gas -- 1.6 (Propane Gas -- 2550 BTU/Cubic Ft)

Length D iameter o f Pipe

of 1/2" 3/4" 1" 1-1/4" 1-1/2" 2"

Pipe Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane Natural Propane

20' 92 56 190 116 350 214 730 445 1100 671 2100 1281 30' 73 45 152 93 285 174 590 360 890 543 1650 1007 40' 63 38 130 79 245 149 500 305 760 464 1450 885 50' 56 34 115 70 215 131 440 268 670 409 1270 775 60' 50 31 105 64 195 119 400 244 610 372 1105 674 70' 46 28 96 59 180 110 370 226 560 342 1050 641 80' 43 26 90 55 170 104 350 214 530 323 990 604

90' 40 24 84 51 160 98 320 195 490 299 930 567 100' 38 23 79 48 150 92 305 186 460 281 870 531 125' 34 21 72 44 130 79 275 168 410 250 780 476 150' 31 19 64 39 120 73 250 153 380 232 710 433 175' 28 17 59 36 110 67 225 137 350 214 650 397 200' 26 16 55 34 100 61 210 128 320 195 610 372

Note: When sizing supply lines, consider possibilities of futur e expansion and increased requiremen ts.

Cubic Feet per Hour bas ed on 0.3" w.c. P ressure Drop

Refer to National Fuel Gas Code for additional information on line sizing.

Capacity of Piping

WARNING

This appliance is equipped for a maximum gas supply pressure of 1/2 pound, 8 ounces, or 14 inches water column.

NOTE: Supply pr essure higher than 1/2 pound requires installation of an additional service regulator

external to the unit.

PRESSURE TESTING SUPPLY PIPING

T est Pressures Abov e 1/2 PSI: Disconnect the heater and manual valv e from the gas supply line which is to be

tested. Cap or plug the supply line.

T est Pr essures Below 1/2 PSI: Before testing, close the manual valve on the heater.

Figure 23 - Gas and Electrical Connections

Install a manual shutoff valve with 1/8 NPT test gauge port

Drip

Side

View

Leg

Allow slack in the electrical cord. Loop excess and bind loosely with wire tie or electrical tape.

10-12

(254-305mm)

diameter

expansion

curve

Grounded Plug-in Cord

10-12 (254-305mm) diameter expansion curve or flexible gas line MUST BE horizontal with or above the gas connection.

End View

DANGER: Do not install gas piping where it

may be exposed to radiant or convection heat.

See Hazard Levels, page 2.

Form RZ-NA-I-TR, Page 18

Page 19

Since the tubular heater does expand and contract, the connection between the supply line and the heater must allow for expansion and contraction. Use either an expansion coil (12" minimum diameter) or, if permitted by local code, a flexible connection. If a flexible connector is installed, use only an CSA certified, stainless steel connector with a maximum length of 24" and a minimum size of 1/2" I.D. If a flexible connector, Option CE3 or CE4, was ordered with the heater, it will be shipped separately. Optional fle xible connectors have the follo wing pressure drops.

2) Open the valve and operate the heater . Measure the gas pressure to the manifold. Normally, adjustments should not be necessary to the factory preset regulator.

If adjustment is necessary, set pressure to correct settings by turning the regulator screw IN (clockwise) to increase pressure. T urn regulator screw OUT (counterclockwise) to decrease pressure.

Consult the valve manufacturer's literature provided with the heater for more detailed information.

WARNING: Strong cleaning solutions or chemical substances must not come in contact with the flexible connector .

BTUH Pressure Drop (Inches W.C.)

Input

50,000 0.25 0.05

75,000 0.25 0.05 100,000 0.25 0.10 125,000 0.50 0.15 150,000 0.75 0.20 175,000 0.80 0.40 200,000 0.90 0.50

A shutoff valve and a drip leg or sediment trap must be provided in the gas supply line at each heater. See Figure 23.

Use a joint compound that is resistant to propane gas at all connections. T est all gas lines using a leak-detecting solution.

Option CE3, 1/2" I.D. Option CE4, 3/4" I.D.

WARNING: All components of the gas supply system must be leak-tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. See Hazard

Levels, page 2.

M a nifold Pressure Settings

B TUH Input G a s Manifol d Pressure

50,000 - 150,000 Natural 3.5" w.c.

175,000 - 200,000 Natural 5" w.c.

50,000 - 150,000 Propane 10" w.c.

Manifold or Orifice Pressure Settings

Measuring manifold gas pressure cannot be done until the heater is in operation. It is included in the steps of the "Check-Test-Start" pr ocedure in Paragraph 16. The following warnings and instructions apply.

Before attempting to measure or adjust manifold gas pressure, the inlet (supply) pressure must be within the specified range for the gas being used both when the heater is in operation and on standby . Incorrect inlet pressure could cause excessive manifold gas pressure immediately or at some future time.

Instructions for Checking Manifold Pressure:

1) With the manual valve (on the combination valve) positioned to prevent flow to the main burners, connect a manometer to the 1/8" pipe outlet pressure tap in the valve. NOTE: A manometer (fluid-filled gauge) is recommended rather than a spring type gauge due to the difficulty of maintaining calibration of a spring type gauge.

15. Electrical Supply and Connections

All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/ NFPA No. 70 (la test edition) or, in Canada, the Canadian Electrical Code, Part I-C.S.A. Standard C22.1. In addition, the installer should be aware of any local ordinances or gas company requirements that might apply . The heater must be electrically grounded and connected to a separately fused circuit with a disconnect as required by the National Electrical Code.

Heaters equipped for 115, 208, or 230 supply voltage have a grounded plug-in cord. Be sure the outlet used provides the appropriate supply voltage. Heaters equipped for 460 supply voltage require a separate disconnect switch and line voltage supply run directly from the main electrical panel to the unit. All external wiring must be within approv ed conduit and have a minimum temperature rise of 60°C. The electrical supply connects at the rear (valve end) of the burner/control box. Make connections as shown on the wiring diagram located on the inside of the service door.

WARNING: If you turn off or disconnect the electrical power supply, turn off the gas. See

Hazard Levels, page 2.

If the heater has field-installed options that require electrical connections, consult the instruction sheet and wiring diagram supplied in the option package.

Control Thermostat

The heater is designed for automatic control from a remotely positioned or optional unit-mounted 24-volt thermostat and is equipped with a terminal strip to facilitate thermostat connections. See Figure 24.

Use either an optional thermostat (Option CL1) or a field-supplied 24volt thermostat. Do not attempt to operate with a line voltage thermostat. Locate a remote thermostat on an inside wall in the heated area but not in the direct path of the infrared rays. See the wiring diagram on page 20 or inside the heater door panel.

Multiple-Heater Control

Options are available to permit control of up to six heaters from a single thermostat or a time clock and single/multiple thermostats. For maximum safety, the multiple control is done in the lo w voltage circuit. Complete instructions are included in each Option Kit. See Paragraph 24.

Figure 24 Thermostat Connections

Terminal

Strip

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 19

Page 20

WIRING DIA GRAM

Form RZ-NA-I-TR, Page 20

Page 21

16. Check Installation and Start-Up

Check the installation prior to start-up:

 Does the installation comply with all electrical and gas codes?  Is the system hung securely according to the instructions? See Para-

graphs 8, 9, and 10. Are the "S" hooks closed?

 Does the installation comply with required clearances? Requirements

are shown in Paragraph 4. Signs are required specifying maximum permissible stacking height underneath the heater.

 If required, was Size or High Altitude Conv ersion Kit installed? See

Paragraph 9.

 Are turbulator strips installed? See Paragraph 10.  Is the vent system installed properly and supported securely? See

Paragraph 12.

 Has the system been checked for gas leaks? Has the gas supply

pressure been verified? Will the gas connection allow for expansion and contraction? See Paragraph 13.

 Is the system level? Before initial start-up, it is important that the

system be checked again to be sure that it is level. Use a spirit level and check the burner and all sections of tubes. If the tubes are not level, hot spots could occur causing premature failure. Check all sections including "L" and "U" tubes. Adjust turnb uckle or chain as required.

Start-Up:

 Bleed all air from the gas supply lines to the heater. Rotate the knob

on the combination valve to the "ON" position.

Set the thermostat to above room temperature. This heater is equipped with a fully automatic ignition; do not attempt to light by hand. After

several seconds, listen for the quiet hum of the combustion air motor. With combustion air motor operating, the spark at the pilot burner will be visible. As the air bleeds from the pilot supply tubing, the pilot flame will try to ignite. When all of the air is gone, the pilot will ignite NOTE: On propane fueled models, it may be necessary to reset the lockout ignition control a number of times by lowering the thermostat below room temperature.

With a fully established pilot flame, the main burner gas flow will be initiated. The indicator light on the burner/control box indicates that the main gas valve is energized. The main burner flame will burn directly off the face of the burner. Natural gas burners will have a blue flame with very little yellow tipping. Propane fueled burners will also have a blue flame, but the flame will have some yellow tipping. (NOTE: On initial start-up, there will be some odor and light smoke released from the tubes and reflectors).

Operate the heater for at least ten minutes to bring it to full temperature to ensure proper operation.

Check installation after start-up:

 With the unit in operation, measure manifold gas pressure. Manifold

pressure for natural gas should be 3.5" w.c. and 10" w .c. f or propane gas. See Paragraph 13.

 Turn the unit off and on, pausing two minutes between each cycle.

Observe for smooth ignition.

 Place "Owner's Envelope" containing the Maintenance and Service

Manual and this manual in a safe, accessible location near the heater. Observe clearances; do not place envelope in direct line of radiant heat.

DANGER: The gas burner in this gas-fired equipment is designed and equipped to provide safe and economically controlled complete combustion. However, if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. These tubular infrared heaters may be safely operated in the vented or unvented mode. FAILURE TO PROVIDE PROPER VENTING OR TO MEET FRESH AIR REQUIREMENTS FOR UNVENTED INSTALLATIONS WILL RESULT IN A HEALTH HAZARD THAT COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.

Always comply with the combustion air requirements in the installation codes and instructions. If combustion air is brought from outside, use only the outside combustion air kit specifically designed for this heater. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Indoor units installed in a confined space must be supplied with air for combustion as required by Code and in this heater installation manual. If two heaters use the same vent terminal, a specially designed dual vent kit must be installed. If the unit is vented, MAINTAIN THE VENT SYSTEM TO BE STRUCTURALLY SOUND AND IN FREE FLOWING OPERATING CONDITION. If the unit is unvented, PROVIDE 4 CFM OF FRESH AIR PER 1000 BTUH'S FOR NATURAL GAS OR 5 CFM OF FRESH AIR PER 1000 BTUH'S FOR PROPANE GAS.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 21

Page 22

Optional Equipment -- Field Installed

This section includes a brief description of most field-installed options. Field-installed option kits include illustrated instructions.

17. Optional Heat Exchanger Tubes

Optional heat exchanger tubes in "U" shape (Option UB3) and "L" shape (Option UC2), and 5-ft straight length (Option UA1) are used to change the configuration of the tubular system. With these optional tubes, the system can be custom-designed to suit the application. All appro ved configuration layouts are illustrated or noted in the Suspension Dimensions and Configuration Drawing booklet provided with each heater. The "L" tube Option Package includes an "L" shaped heat exchanger tube, tube connection hardware, components to field-assemble an L-shaped reflector, and an illustrated instruction sheet. Tube connection is the same as for straight tubes; see Paragraph 9, Figure 11. The "U" tube Option Package includes a "U" shaped heat exchanger tube, connection hardware, components to field-assemble a "U" shaped reflector, and an illustrated instruction sheet. Tube connection is the same as for straight tubes; see Paragraph 9, Figure 11. The 5-foot Heat Exchanger Option Package includes a 5-ft tube, tube connection hardware, a 5-ft reflector, and two reflector brack ets. Tube suspension and installation instructions are the same as for a 10-ft heat exchanger tube. See Paragraphs 7, 9 and 10. The configuration must meet the guidelines listed below .

ALL of the following conditions are met, the configuration may be custom-

If ized by replacing any 10-ft heat exchanger tube(s) with one or two 5-ft heat exchanger tubes.

1) Do not deviate from the specified minimum or maximum length of straight tubes for the size of heater being installed.

BTUH Size (000)

50 20 feet 30 feet 25 feet

75 20 feet 40 feet 25 or 30 feet 100 30 feet 50 feet 35 or 45 feet 125 40 feet 50 feet 45 feet 150 50 feet 60 feet 55 feet 175 50 feet 70 feet 55, 60, or 65 feet 200 50 feet 70 feet 55, 60, or 65 feet

2A) Sizes 100, 125, and 150 -- DO NOT replace the first 10-ft heat exchanger tube with a 5-ft tube. Sizes 100, 125, and 150 require a minimum

of 20 feet of straight tube length before an "L" or "U" shape is installed.

Minimum

Length

Maximum

Length

Alternate Allowable

O verall Lengths

3) Do not install a 5-ft heat exchanger tube in place of a 10-ft tail pipe. A 10-ft tail pipe is required in all conf igurations.

4) On a "U" configuration, the straight tube length on the burner side of the "U" must be equal to or longer than the tube length on the exhaust side.

5) Adjust both the overall dimension and the suspension point dimensions shown in the configuration drawing when using a 5-ft heat exchanger tube. Reduce or increase appropriate dimensions by 5 feet. (5-ft heat exchanger tubes require a suspension point.)

18. Hanger Kit, Option CK11

This option kit includes 50' of chain with a 200 lb working capacity and 18 "S" hooks. Minimum chain, "S" hooks, and/or turnbuckle length between the tubes and the building suspension points is 12". If turnbuckles are included in heater suspension, use either optional turnbuckles (Paragraph 18) or field-supplied turnbuckles of steel or malleable iron.

IMPORTANT: Chain in Option CK11 has links consisting of two loops. When cutting 50' chain to required lengths, be certain to remove both loops of the "cut" link.

19. T urnbuckle Kit, Options CK12-18

Tubular infrared heaters must be level. For ease in leveling the system, the use of turnbuckles is recommended. The optional turnbuckle kit provides a turnbuckle as illustrated in Figure 25 to attach to the "S" hook at each heater hanger bracket.

Figure 25 - Turnbuckle in Optional T urnb uckle Kits

Right

hand

thread

Add nut to lock turnbuckle.

Burner

Box

9' 7-1/2"

Combustion

Chamber

Tube

10' Heat

Exchanger Tube

-- DO NOT

replace with

a 5' tube

2B) Sizes 175 and 200 - DO NOT replace either the first or second 10-ft heat exchanger tube with a 5-ft tube. Sizes 175 and 200 require a minimum

of 30 feet of straight tube length before an "L" or "U" shaped tube is installed.

2' 9' 7-1/2"

Combustion

Chamber

Tube

9' 8"

10' Heat

Exchanger

Tube

Burner Box

DO NOT re place either

with a 5' tube

Form RZ-NA-I-TR, Page 22

9' 8"

or "U" Heat

Exchanger

9' 8"

10' Heat

Exchanger

Tube

"L"

Tube

"L"

or "U" Heat

Exchanger

Tube

T urnbuckle assembly rated for at least a 200 lb working load.

Left hand thread

20. Combustion Air Inlet Kit,

Option DE2

Combustion air can either come from the heated space or be piped from the outside. Combustion air should be piped from the outside if (1) the pressure in the building is negative, (2) the atmosphere is dirt laden, (3) the atmosphere contains any substance that will cause toxic gas when passed through a flame, or (4) the heater is installed in a tightly closed room that does not provide required air for combustion. If outside combustion air is required, the optional

Page 23

combustion air inlet kit must be installed. See requirements in Paragraph 12.

Each kit includes inlet air pipe expandable to three feet, a terminal cap, connection hardware, and illustrated installation instructions.

side shield is included in the installation, a screw must be inserted at each tube joint to prevent the tubes from turning. Follow the illustrated instructions included in the side shield package.

23. Optional Reflector Gap and End Covers, Options CD21-27

The optional gap covers are designed to provide the infrared system with a continuous reflector while still allowing for system expansion. The end covers are designed to "close" the vertical space on the ends of the reflector length. Optional end covers may only be used when gap covers are installed. Reflectors on systems with gap covers cannot be rotated. Gap Covers are Option CD21-26; End Covers are Option CD27. Each option kit includes illustrated instructions.

Figure 26 -

Combustion Air Inlet

Kit, Option DE2

21. Dual Vent Kit, Option CC5

The dual vent option kit permits venting of two of these heaters through only one opening in the roof or side wall of a building. The concentric design of the vent allows each of the two heaters to be safely operated totally independent of the other. The tw o heaters may be controlled by the same or different thermostats. Heaters vented through the optional dual vent do not have to match in capacity, length or configuration. The adapter box in the dual vent kit converts the two separate vent pipe runs into the concentric vent terminal arrangement. The specially designed dual vent adapter box attaches indoors, close to the wall or roof opening.

Each dual vent option kit includes the adapter box, a 4" vent cap, a 6" vent cap with concentric opening for passage of 4" vent pipe, adapter box mounting brackets, and complete instructions. Vent pipe is field supplied. Use only single wall metal pipe.

24. Multiple Heater Control, Options CL31 and 32

These multiple heater control options permit the control of up to six heaters (one master

Figure 28 - Multiple Heater Control Wiring with Option CL31 and/or CL32

Figure 27 Dual V ent Kit, Option CC5

22. Optional Side Shield, Options CD13-20

The optional side shield hangs vertically from the reflector brackets. Installation of the optional side shield allows for less clearance from one side of the heater. See Paragraph 4.

The side shield is modular with two sections required per 10-ft tube. Install the two additional reflector brackets required for the side shield at the same time as the two standard reflector brackets. With a side shield attached, reflectors may not be rotated more than 30o. When an optional

and five slave units) from a single thermostat or a time clock and single/multiple thermostats. For maximum safety, the multiple control is done in the low voltage circuit. See wiring diagram in Figure 28.

25. Optional Unit-Mounted Thermostat Bracket Kit, Option CM3

The optional thermostat bracket kit allows attachment of the controlling thermostat to the burner/control box. The bracket attaches at the same location as the thermostat strip and includes a junction box for mounting the thermostat. Complete instructions are included with the option kit. The thermostat is not included in the kit. The low voltage thermostat may be either an optional thermostat (Option CL1) or an equivalent fieldprovided thermostat.

Form RZ-NA-I-TR, Mfg No. 121027 Rev 5,

Page 23

Page 24

Index (by page number)

Accessory Cartons ..................................................................... 5

High Altitude.............................................................................. 2

Burner/Control Box Packages.................................................... 4

Check Installation and Start-Up ............................................... 21

Clearances to Combustibles ....................................................... 3

Install Combustion Air Inlet Co ver ............................................ 7

Combustion Air........................................................................ 17

Combustion Air Inlet Kit.......................................................... 22

Configurations ........................................................................... 3

Confined Space ........................................................................ 17

Connecting Tubes....................................................................... 9

Conversion Size Labels.............................................................. 6

Description................................................................................. 2

Dual V ent Kit ........................................................................... 23

Electrical Characteristics............................................................. 3

Electrical Supply and Connections ........................................... 19

Gas Piping and Pressures ........................................................ 17

Gas Type and Supply Gas Pressure ........................................... 3

Hanger Kit ............................................................................... 22

HAZARD INTENSITY LEVELS ............................................ 2

Install the Heat Exchanger Tube(s)............................................. 8

Optional Heat Exchanger Tubes............................................... 22

High Altitude Operation .............................................................. 5

Installation Codes........................................................................ 2

Location and Mounting Height .................................................. 3

Manifold or Orifice Pressure Settings...................................... 19

Multiple Heater Control Options.............................................. 23

Change Burner Orifice ............................................................... 6

Packaging ................................................................................... 4

Prepare Burner/Control Box ...................................................... 6

Install Optional Reflector End Cover ....................................... 12

Install Optional Reflector Gap Covers ..................................... 12

Reflect or Retai ners ................................................................... 12

Install Reflectors ...................................................................... 12

Change Air Restrictor Plate ........................................................ 6

Optional Side Shield ......................................................... 12, 23

Specifications ............................................................................. 3

Start-Up ................................................................................... 21

Suspend the Combustion Chamber T ube/Burner Box Assy ....... 7

Suspension Dimensions and Preparation ................................... 5

Suspension Points...................................................................... 5

Thermostat .......................................................................... 19, 23

Tube Cartons ............................................................................... 4

Install the Turb ulator Strip.......................................................... 9

Turnb uckle Kit ......................................................................... 22

Uncrating ................................................................................... 4

Unvented Installation ............................................................... 16

V ent Pipe Type .......................................................................... 13

V ent T able ................................................................................ 13

V ent T erminal Arrangements .................................................... 14

V ent T erminal Clearances ......................................................... 15

Warranty...................................................................................... 2

References: Form RZ-NA

*Configuration Drawings and Suspension Dimensions ..........607

Flux Density (Floor Coverage) Diagrams................................ 609

*Limited W arranty .............................................................. WF005

*Operation/Maintenance/Service ................................... 456-OMS

Replacement parts ....................................................................709

* Included with the heater. Other material is available through

your distributor.

Form RZ-NA-I-TR, Page 24

1-800-695-1901 www.RezSpec.com

MANUFACTURER OF GAS, OIL, ELECTRIC HEATING AND VENTILATING SYSTEMS Trademark Note: Reznor® and Infra-Rez® are registered in the United States and other countries. 704 OG POD Form RZ-NAI-TR

Thomas & Betts TR, TR-H Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual