Thomas & Betts TR, TR-H Installation Manual
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
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
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
mm
1981
mm
mm
2134 305 762 1219 610 152
0-30
Front
30 30 48 18 36 12
762 762 1219 457 914 305
mm
1067 1067 1676 813 1067 305
mm
mm
1372 1372 1981 914 1372 305
Horizontal Clearances
Burner
Top*
End
12
30 48
305
762 1219
12
30 48
With Reflector Positioned
o
Front Rear Front
Rear
Heat
Exch anger
Bend (U o r L )
o
31-45
Exhaust
End
24 6
610 152
24 6
0-30o wit h
Si de Sh i e l d
**
Vent
Rear
Front
of
Reflector
Top of Reflector
Below the Reflector
or Below the Tube
HORIZONTAL REFLECTOR
Burner
End
Exhaust End
Rear
of
Reflector
Optional
Side
Shield
HORIZONTAL CLEARANCES
Figure 1 - Clearance Orientation
Front
of
Reflector
Top of Reflector
Rear
of
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
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
M
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
M
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
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
4.
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
A
At least 12
(305mm) of
chain MUST
BE used for
proper expansion
movement.
Page 5
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
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
PO
IM
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
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.
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