INST INSTALLA ALLA ALLATION and OPERA

Section

INST ALLA TION and OPERA TING INSTR UCTIONS or

GAS-FIRED INFRA-RED RADIANT TUBE HEATERS

ANSI Z83.20b-2004

CSA 2.34b-2004

MOST RECENT EDITION

PLACE NEAR HEATING UNIT

ERXL-60,

MODELS

ERXL-80

ERXL-80S, ERXL-100

ERXL-100S, ERXL-125

ERXL-125S ERXL-150

ERXL-150L, ERXL-175

ERXL-175L

WARNING:

IMPROPER INSTALLATION, ADJUST-

MENT, ALTERATION, SERVICE OR MAINTENANCE CAN

CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ

THE INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS THOROUGHLY BEFORE INSTALLING

OR SERVICING THE EQUIPMENT

Enerco Technical Products, Inc.

4560 W.160th St.

Cleveland, Ohio 44135

Phone: 800-251-0001

Stock No. 18677XL 8/05 Rev. A

18677 Rev. A 8/05

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Section



18677 Rev. A 8/05

01 Section 1

Warnings

WARNING

FIRE OR EXPLOSION HAZARD

Can cause property damage, severe injury or death.

1) Read this manual carefully before installing or servicing this equipment. Improper installation, service or maintenance can cause property damage, injury or death.

2) Check clearances given on the outside of each burner to make sure the product is suitable for your application.

3) Installer must be a trained, experience service technician or representative.

4) All service must be performed only by a trained service technician or representative.

5) After installation is complete, check product operation as provided in these instructions.

WARRANTY

ENERCO warrants the Infra-Red Heaters manufactured and sold by its Industrial Heating Division will be free from defects in material and workmanship.

ENERCO pro-rated tube warranty shall continue in effect until the expiration of five (5) years from the date of shipment or original tube heat exchangers by Enerco.

Parts, assemblies, control etc. furnished by ENERCO suppliers will carry a one (1) year warranty or applicable warranties of the suppliers.

The sole responsibility of ENERCO under this warranty shall be to replace or repair any part for which a written claim is made to ENERCO within the time limit of the warranty, which is returned upon request to

ENERCO -- F.O.B. Cleveland, Ohio -- or F.O.B. an ENERCO authorized service facility and which is proved to be defective upon inspection By

ENERCO.

This warranty shall not apply to any part or product which has been subjected to misuse or neglect, damage by accident, or rendered defective by reason of improper installation. This warrant is in lieu of any and all other warranties, expressed or implied, and of any other responsibility by

ENERCO for parts or products sold by ENERCO, including consequential or special damages.

18677 Rev. A 8/05



Section 1

Warnings

WARNING

FAILURE TO FOLLOW THESE

INSTRUCTIONS CAN CAUSE PROPERTY

DAMAGE, SEVERE INJURY OR DEATH:

FIRE OR EXPLOSION HAZARD: Combustibles

Failure to maintain the specific minimum clearances to combustibles could result in a serious fire hazard. Do not locate flammable or combustible materials within this distance. Do not locate in hazardous atmospheres containing flammable vapors or combustible dust. Installations in public garages or airplane hangers are permitted when in accordance with ANSI

Z83.6 and NFPA-409 and 88 codes.

FIRE OR EXPLOSION HAZARD: Vehicles

Minimum clearances must be maintained from vehicles parked below the heater. Signs should be posted in storage areas to specify maximum stacking height to maintain required clearances to combustibles.

FIRE OR EXPLOSION HAZARD: Gas Connection

There is an expansion of the radiant pipe with each firing cycle, and this will cause the burner to move with respect to the gas line. This can cause a gas leak resulting in an unsafe condition if the gas connection is not made strictly in accordance with (Figure 18) of these instructions.

FIRE OR EXPLOSION HAZARD: Ignition

This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

MECHANICAL HAZARD: Suspension

Use appropriate suspension hardware, beam clamps (rod or perforated strap) and turnbuckles at predetermined locations. The weight and normal movement of the heating system may cause support failure if the following minimum suspension requirements are not met: 1) distance between supports must be 10 ft. or less; 2) chain size must be 1/0 minimum or equivalent. Failure of the supports can cause property damage, severe injury, or death.

02

More WARNINGS on next page

18677 Rev. A 8/05



03 Section 1

Warnings

IMPORTANT


INSTRUCTIONS CAN CAUSE PROPERTY

DAMAGE OR PERSONAL INJURY

Do not use in an atmosphere containing halogenerated hydrocarbons or other corrosive chemicals. Some compounds in the air can be drawn into the equipment and can cause an accelerated rate of corrosion of some parts of the heat exchanger. The use of such chemical compounds in or near the enclosure should be avoided where a longer life of the burner, tubing and other parts is desirable.

Caution should be used when running the system near combustible material such as wood, paper, rubber, etc. Consideration should be given to partitions, storage racks, hoists, building construction, etc. (Tabe 1, Section 3) gives minimum acceptable clearances to combustibles. Clearances as shown in Table 1 are not for use in four-sided enclosures.

If the building has a slight negative pressure or contaminants are present in the air, an outside combustion air supply to the heater is strongly reccomended.

CAUTION


INSTRUCTIONS CAN CAUSE DAMAGE, TO

THE SYSTEM COMPONENTS

Do not high pressure test the gas piping with the burner connected.

Failure to follow this procedure will exceed the pressure rating of buner gas controls and this will require complete replacement of these parts.

This heater is designed for heating non-residential indoors spaces. These instrcutions, the layout drawing, local codes and ordinances, and applicable standards such as apply to gas piping, electrical wiring, venting, etc., must be thouroughly understood before proceeding with the installation.

18677 Rev. A 8/05



WARNINGS & WARRANTY

Read this sections carefully. Improper installation adjustment, operation or maintenance can cause property damage, injury or death

INDEX

INTRODUCTION

Checking Shipment - Installer Responsibility

INSTALLATION: Planning

National codes - Critical Considerations - Installation Procedure

Accessory parts Lists - Clearances to Combustibles - Parts list for packaged

Ener-Radiant III Heaters

INSTALLATION: Assembly

Assembly Overview - Couplings - Suspension - Tube Clamp

Turbulator - Burner

INSTALLATION: Venting & Ducting

General Requirements - Unvented Operation - Horizontal Venting

Vertical Venting - Common Venting - Outside Air Supply

INSTALLATION: Gas Piping

Sizing - Installation - Flex Gas Connection

INSTALLATION: Wiring

Line Voltage Thermostat Wiring - Low Voltage Thermostat Wiring

Burner Internal Wiring - Ladder Diagram

OPERATION/MAINTENANCE

Operation - Maintenance - Troubleshooting

APPENDICES

Replacement Parts I - Engineering Specifications II

General Specifications III

1 1-3

2

3

4

5

6-14

4 15-20

5 21-26

6

7

8

9

27

28-31

32-36

37-40

04

18677 Rev. A 8/05



05 Section 2

Introduction

INTRODUCTION

Section 2

Ener-Radiant XL models are low-cost, field assembled infrared heaters that are easy to install and require only minimal maintenance. They are designed to provide years of economical operation and trouble-free service.

Checking Shipment

Check the shipment against the Bill of Lading for shortages. Also check for external damage to cartons. Note any shortages, and/or external damage to cartons on the Bill of Lading in the presence of the delivery trucker. The delivery trucker should acknowledge any shortages or damage by initializing this “noted” Bill of Lading. Immediately report any claims for damage material, or shortages that were not evident at the time of shipment, to the carrier and your

ENERCO Factory Representative.

Installer Responsibility

All heaters and associated gas piping should be installed in accordance with applicable specifications and this installation made only by firms (or individuals) well qualified in this type of work. Consult local building inspectors, Fire Marshals or your local ENERCO Representative for guidance.

Ener-Radiant XL heaters are installed on the basis of information given in a layout drawing, which together with the cited codes and regulations, comprise the basic information needed to complete the installation. The installer must furnish all needed material that is not furnished as standard equipment, and it is his responsibility to see that such materials, as well as the installation methods he uses result in a job that is workmanlike and in compliance with all applicable codes.

ENERCO Factory Representatives have had training and experience in the application of this equipment and can be called on for suggestions about installation which can save material and money.

18677 Rev. A 8/05



Section 3

Planning

PLANNING

Section 3

The following codes and instructions should be followed when planning the installation of the Ener-Radiant XL heater. In addition to these instructions, the warnings in (Section 1 ) must be carefully adhered to since improper installation may lead to property damage, injury or death.

National Standards and Applicable Codes

Gas Codes: The type of gas appearing on the nameplate must be the type of gas used. Installation must comply with local codes and recommendations of the local gas company, and the

National Fuel Gas Code, ANSI Z223.1 - latest revision, (same as NFPA bulletin 54).

•

Clearance between the heater and its vent and adjacent combustible material (which is part of the building or its contents) shall be maintained to conform with the Standard for

Installation of Gas Appliances and Gas piping, NPFA-54 / ANSI Z223.1 - latest revision,

National Fuel Gas Code.

Aircraft Hangers: Installation in aircraft hangers must be in accordance with the Standard for Aircraft

hangers, ANSI / NFPA-409 - latest revision.

•

Heaters in aircraft storage or service areas shall be installed at a height of 10 feet above the upper surface of wings or engine enclosures of the highest aircraft which may be housed in the hanger. (This should be measured from the bottom of the heater to the wing or engine enclosure, whichever is highest from the floor.)

•

In other sections of aircraft hangers, such as shops or offices, heaters must not be installed less than 8 feet above the floor.

•

Heaters installed in aircraft hangers shall be located so as not to be subjected to damage by aircraft, cranes, moveable scaffolding or other objects.

Public garages: Installations in garages must be made in accordance with the Standard for parking

Structures, NPFA-88A - latest revision or the Standard for Repair Garages, NFPA-88B latest revision.

•

•

Heaters must not be installed less than 8 feet above the floor. Minimum clearances to combustibles must be maintained from vehicles parked below heater.

When installed over hoists, minimum clearances to combustibles must be maintained from the uppermost point on the hoist.

Electrical: the heater must be electrically grounded in accordance with the National Electrical

Code, ANSI / NPFA-70 - latest revision. Wiring must conform to the most current

National Electrical Code, local ordinances, and any special diagrams furnished.

Venting: the venting must be installed in accordance with NPFA-54 / ANSI-Z223.1 - latest

revision, National Fuel Gas Code. Partial information with regard to this code is provided in (Section 5) of this installation manual with regard to size and configurations for venting arrangements.

•

Any portion of flue pipe passing through a combustible wall must be dual insulated or have an approved thimble. Refer to ANSI-Z223.1 - latest revision.

Hazardous

Locations:

Where there is the possibility of exposure to combustible airborne material or vapor, consult the local Fire Marshal, the fire insurance carrier or other authorities for approval of the proposed installation.

18677 Rev. A 8/05



06

07 Section 3

Planning

Critical Considerations

Ener-Radiant XL is a suspended heater. Therefore, its stability, flexibility, and safety are very important. Before starting installation, be sure the system can meet the following requirements.

•

Maintain specified clearances to combustibles, and safe distance from heat-sensitive material, equipment and work stations.

•

Provide a suspension with vertical length of chain or swinging rod which has at least 2 inches of horizontal travel for each burner in a straight run. Be sure the suspension system is sufficiently flexible to accommodate thermal expansion which occurs as the system heats up (see Figure 5).

•

Provide access to burners for servicing, preferable on both sides, above and behind for burner removal.

•

Provide a minimum of 18 inches of clearances between burners and building walls.

(Always observe minimum clearances to combustibles).

•

Be sure the heater has a downward pitch of one-half inch per 20 feet away from the burner.

•

Provide signs in storage areas to specify maximum stacking height to maintain required clearances to combustibles.

•

Plan location supports (see Figure 2). Locate a support near all elbows.

Installation Procedure

Don’t

Do

Take maximum advantage of the building upper structure, beams, joist, purlins, etc., from which to suspend the heater. There is no unique sequence for installation of the tubing. On-site observation will usually reveal a logical sequence. Begin the installation at the most critical dimension. This could save time. Watch for swinging doors, overhead cranes, car lifts, etc.

Reflectors and tubing can be installed as you move along. Carefully adjust system pitch at each position to level the heater. Pitch down one half inch in 20 feet (away from Burner)

•

Pressure test the gas line using high pressure (greater than 1/2 PSIG) without closing the high pressure shut-off cocks. Failure to do so will result in damage to the burners.

•

Familiarize yourself with local and national codes.

•

Develop a planned procedure which will conserve material and labor on the job.

•

Check to see that all material and equipment is on the job before starting installation.

•

Allow for thermal expansion of the hot tube.

•

Install the gas connector only as shown in instructions (see Figure 18).

•

Have slip joints where required between reflectors keep them from buckling or coming apart.

•

Provide 1 sq inch of free air opening to each 1,000 BTU/hr of heater input (but not less than 100 sq inches) in enclosed spaces. One opening should be within 12 inches of the top and within 12 inches of the bottom of the enclosure.

18677 Rev. A 8/05



Stock Number

10371

10392

17370

03445

03447

16401

18677A

F106414

F106415

19021

06430

Section 3

Planning

ACCESSORY PARTS LIST

Description

Thermostat 24 volt

Thermostat 120 volt

Chain Kit

Turbulator 10’ Section

Turbulator 5’ Section

24” Stainless Steel Flexible Gas Connector

Installation Manual / ER3LSeries

180 o

U-Tube Accessory Kit

90 o

Elbow Accessory Kit

Vent Adapter

Vent Cap

F111751

F111752

F111753

F111754

F111755

Installation kit for 20’ tube heater





Installation kit includes 24-volt thermostat, vent cap, 24” stainless steel flexible gas connector, gas shutoff vavle, and chair kits required to hang heater.

08

18677 Rev. A 8/05



09 Section 3

Planning

Clearances To Combustibles

TABLE 1:

Minimum Clearances to Combustibles (Use figure 1 on page 10 as a Guide)

Refelctor Type

Standard Reflector

(Horizontal)

45 o

Reflector Tilt

U-Tube Standard

(Horizontal)

U-Tube Opposite 45 o

U-Tube Full 45

Unvented

o

Position ERXL-60 ERXL-80 ERXL-100 ERXL-125 ERXL-150 ERXL-175

A

B

C

D

6”

30”

55”

30”

6”

36”

55”

36”

6”

36”

74”

36”

6”

36”

87”

36”

6”

36”

87”

36”

8”

36”

87”

36”

A

B

C

F

A

B

C

D

E

F

A

B

C

A

B

C

E

F

12”

30”

55”

36”

60”

6”

30”

55”

30”

12”

30”

55”

60”

12”

30”

55”

36”

60”

18”

36”

55”

36”

60”

6”

36”

55”

36”

18”

36”

55”

60”

18”

36”

55”

36”

60”

18”

36”

74”

36”

60”

6”

36”

74”

36”

18”

36”

74”

60”

18”

36”

74”

36”

60”

18”

36”

87”

36”

60”

6”

36”

87”

36”

18”

36”

87”

60”

18”

36”

87”

36”

60”

18”

36”

87”

36”

60”

6”

36”

87”

36”

18”

36”

87”

60”

18”

36”

87”

36”

60”

18”

36”

87”

60”

8”

36”

87”

36”

18”

36”

87”

36”

60”

18”

36”

87”

36”

60”

Above A 36” 36” 36” 36” 36” 36”

WARNING

FIRE OR EXPLOSION HAZARD

Can cause property damage, severe injury or death.

In all situations, clearances to combustibles must be maintained. Failure to observe clearances to combustibles may result in property damage, severe injury, or death.

Minimum clearances must be maintained from vehicles parked below the heater. Signs should be posted in storage areas to specify maximum stacking height to maintain required clearances to combustibles.

Caution should be used when running the system near combustible materials such as wood, paper, rubber, etc. Consideration should be given to partitions, storage racks, hoists, building construction, etc.

Table 1 gives minimum acceptable clearances to combustibles. Clearances as shown in Table 1 are not for use in four-sided enclosures.

18677 Rev. A 8/05



Clearances To Combustibles

FIGURE1:

Clearances to Combustibles (Refer to Table 1 on page 9)

Section 3

Planning

10

Standard Reflector

45 o Reflector Tilt

“U”-Tube, Standard

“U”-Tube, Opposite 45 o

Front and Back Clearance



“U”-Tube, Full 45 o

18677 Rev. A 8/05

11 Section 3

Planning

Parts List for Packaged Ener-Radiant XL Tube Heaters

ITEM STOCK DESCRIPTION

1 F107400XL ERXL-60 NG COMP / 20’

2 F107401XL ERXL-60 LP COMP / 20’

3 F107402XL ERXL-80 NG COMP / 30’

4 F107403XL ERXL-80 LP COMP / 30’

5 F107412XL ERXL-80S, NG COMP / 20’

6 F107413XL ERXL-80S, LP COMP / 20’

7 F107414XL ERXL-100S, NG COMP /30’

8 F107415XL ERXL-100S, LP COMP / 30’

9 F102650XL ERXL-60 NG / BRN & Cont Box

10 F102651XL ERXL-60 LP / BRN & Cont Box

11 F102652XL ERXL-80S, ER3-80 NG /BRN & Cont & Box

12 F102653XL ERXL-80S, ER3-80 LP / BRN & Cont & Box

13 F102654XL ERXL-100S / BRN & Cont Box / NG

14 F102655XL ERXL-100S / BRN & Cont Box / LP

15 F106401XL ERXL-100S / TUBE SYS ONLY / 30’

16 F106404XL ERXL-60, 80S /TUBE SYS ONLY / 30’

17 F106405XL ERXL-80 / TUBE SYS ONLY / 30’

18 00418A REFELECTOR / T.H.

19 03445

20 03447

21 06413

22 14585

23 02753

24 14612

TURBULATOR BAFFLE 10’

TURBULATOR BAFFLE 5’

TUBE H.E. 4” O.D. x 10’

HANGER / TUBE & REFELECTOR

FRONT CASTING

TUBE COUPLING ASSEMBLY

NUMBER REQUIRED

X

X

X

X

X

X

X

X

1

1

1 1

1 1

1

1

1 1

1 1 1 1

1 1

2 2 3 3 2 2 3 3

1 1 1 1 1 1

1 1

1 1 2 2 1 1 2 2

4 4 6 6 4 4 6 6

1 1 1 1 1 1 1 1

1 1 2 2 1 1 2 2

*Items 15, 16, 17 include the following items: 18, 19, 20, 21, 22, 24.

18677 Rev. A 8/05





Section 3

Planning

12

Figure “A” - Assembly

Model ERXL-60, ERXL-80S

Figure “B” - Assembly

Model ERXL-80

Figure “C” - Assembly

Model ERXL-100S

See Page 11 for PARTS LIST

18677 Rev. A 8/05

13 Section 3

Planning

Parts List for Packaged Ener-Radiant XL Tube Heaters

ITEM STOCK DESCRIPTION

1 F107404XL ERXL-100 NG COMP / 40’

2 F107405XL ERXL-100 LP COMP / 40’

3 F107406XL ERXL-125 NG COMP / 50’

4 F107407XL ERXL-125 LP COMP / 50’

5 F107408XL ERXL-150, NG COMP / 50’

6 F107409XL ERXL-150, LP COMP / 50’

7 F107420XL ERXL-175, NG COMP / 50’

8 F107421XL ERXL-175, LP COMP / 50’

9 F107416XL ERXL-125S NG COMP / 40’

10 F107417XL ERXL-125S LP COMP / 40’

11 F107418XL ERXL-150L NG COMP / 60’

12 F107419XL ERXL-150L LP COMP / 60’

13 F107422XL ERXL-175L NG COMP / 60’

14 F107423XL ERXL-175L LP COMP / 60’

15 F102654XL ERXL-100 NG / BRN & CB

16 F102655XL ERXL-100 LP / BRN & CB

17 F102656XL ERXL-125S, ERXL-125 NG / BRN & CB

18 F102657XL ERXL-125S, ERXL-125 LP / BRN & CB

19 F102658XL ERXL-150L, ERXL-150 NG / BRN & CB

X

1

X

1

NUMBER REQUIRED

X

1

X

1

X

X

X

X

X

1

X

1

X

X

X

X

1 1

20 F102659XL ERXL-150L, ERXL-150 LP / BRN & CB

21 F102660XL ERXL-175L, ERXL-175 NG / BRN & CB

22 F102661XL ERXL-175S, ERXL-175 LP / BRN & CB

23 F106403 ERXL-150L / TUBE SYS / 60’

24 F106406

25 F106407

ERXL-100, ERXL-125S / TUBE SYS / 40’ 1 1

ERXL-125, ERXL-150 / TUBE SYS / 50’

26 00418A

27 06413

28 06423

29 14585

30 14587

31 14612

REFLECTOR / T.H.

TUBE H.E. 4” O.D. x 10’

TRANSITION TUBE ASSEMBLY

HANGER / TUBE & REFLECTOR

TUBE SUPPORT -- 5”

TUBE COUPLING ASSEMBLY

1

1

1

1

1

1

1

1

1 1

1

1

1

4 4 5 5 5 5 4 4 6 6

3 3 4 4 4 4 3 3 5 5

1 1 1 1 1 1 1 1 1 1

8 8 10 10 10 10 8 8 12 12

1 1 1 1 1 1 1 1 1 1

3 3 4 4 4 4 3 3 5 5

*Items 23, 24, 25 include the following items: 26, 27, 28, 29, 30.



18677 Rev. A 8/05

Section 3

Planning

14

Figure “F” - Assembly

Model ERXL-150L, 175L

Figure “D” - Assembly

Model ERXL-100, ERXL-125S

Figure “E” - Assembly

Model ERXL-125,

ERXL-150, ERXL-175

See Page 13 for PARTS LIST

18677 Rev. A 8/05



15 Section 4

Installation & Assembly

INSTALLATION & ASSEMBLY

FIGURE 2:

Ener-Radiant XL Overview Key

Section 4

FIGURE 2a: Ener-Radiant XL Model ERXL-60, ERXL-80S, Assembly Overview

20 ft. Exchanger length. 21 ft. - 4 in. Total Heater length. 4 Suspension points as indicated

FIGURE 2b: Ener-Radiant XL Model ERXL-80, Assembly Overview

30 ft. Exchanger length. 31 ft - 4 in. Total Heater length. 6 Suspension points as indicated.

18677 Rev. A 8/05



FIGURE 2c: Ener-Radiant XL Model ERXL-100S, Assembly Overview


16

FIGURE 2d: Ener-Radiant XL Model ERXL-100, ERXL-125S


FIGURE 2e: Ener-Radiant XL Model ERXL-125, ERXL-150, ERXL-175


FIGURE 2f: Ener-Radiant XL Model ERXL-150L, ERXL-175L


18677 Rev. A 8/05



17 Section 4


Assemble the heater components as shown in Figures 2a, 2b, 2c, 2d, 2e and 2f. Optional reflector configurations are shown in (Figure 1). Install appropriate suspension hardware, beam clamps, chain or rod at predetermined locations. Adjustment of chain length will provide uniform pitch.

Couplings:

Tube and tube fittings are connected by wrap-around couplings which clamp by means of a tapered, hammer-driven lock member. The starting ends of the coupling and lock member are identified by

1/4” holes which are put together when starting assembly. Be sure the tube ends are in line and tube ends butt against stop pin(s) inside coupling. The slide bar is to be hammer-driven to a point of securing the coupling snugly to the tubes. Over-driving will result in distortion of the coupling or slide bar lip to a point decreasing the holding capability of the coupling. Coupling should be tight when the slide bar is + 2” from the end of the coupling. (See Figure 3).

FIGURE 3: Coupling Assembly

TURBULATOR BAFFLE ASSEMBLY INSTRUCTIONS

For ease of field installation, the turbulator should be installed in the tube before hanging the system.

Use the following procedure:

1) Assemble turbulator pieces by “twisting” matching ends together.

2) Insert a long wire (11 ft. minimum) down the length of the tube.

3) Attach the wire to the hole in the tab on the adapter piece.

4) Using the wire, pull the assembled turbulator into the tube from opposite side.

5) Pull the turbulator through until just the tab commes out. Detach the wire.

6) Bend the tab around the tubing. When installing the tube, the tab will be locked in place by the adapter.

18677 Rev. A 8/05



FIGURE 4: Installation of Elbow & Coupling (optional equipment)

Elbow package:

Stk. #F106415 Elbow Pacakge includes:

(1) elbow and (1) coupling. Install elbow into radiant tube sequence where plans indicate a 90 o

bend (see Figure 4).

18

Elbow Fitting Dimensions

90 o

Elbow

Stk #F106414 U-Tube Package includes:

(1) U-tube and (1) coupling. Install U-tube elbow into radinat tube sequnce where plans indicte a 180 o

bend (see Figure 4).

U-Tube Fitting Dimensions



180 o

U-Tube

18677 Rev. A 8/05

19 Section 4


FIGURE 5: Typical Suspension Details

Chain Kit - Stk #17370

One chain kit will suspend one 10 ft.

section of tube and one 10 ft. section of reflector.

FIGURE 6: Tube & reflector Hanger



18677 Rev. A 8/05

FIGURE 7: Mounting Flange / Tube Detail

1) Insert tube 06413 into front casting to point (A).

2) Tighten set screws marked (B) until snug.

3) After both set srews are sung, turn each additional 1/4 turn to secure tube in place.

FIGURE 8: Burner Box / Transition Tube Detail

20



18677 Rev. A 8/05

21 Section 5

Vent / Ducting

VENTING / DUCTING

Section 5

General Requirements

Heater must be vented in accordance with specification ANSI Z223.1 - latest revision. Partial information relating to this specification is provided in this section with regard to size and configurations for venting arrangements ( see Figures 12, 13, 14, 15, 16). For complete information consult ANSI Z223.1 - latest revision and applicable local codes. Use the following guidelines to help insure an adequate, safe venting arrangement.

a) Be sure that method selected for venting heater complies with all codes as required for each particular location.

b) Exhaust end of heater will accept a four (4”) inch flue pipe using the flue pipe adapter.

c) Heater may be vented to the outdoors either vertically or horizontally.

d) If heater is to be vented horizontally:

1) Vent must exit building not less than seven (7’) feet above grade when located adjacent to public walkways.

2) Vent must terminate at least three (3’) feet above any forced air inlet located within ten feet (10’)

3) Vent must terminate at least four (4’) feet below, four (4’) feet horizontally from, or one

(1’) foot above any door, window, or gravity inlet into any building.

4) Vent terminal shall be located at least twelve (12”) inches from any opening through which vent gases could enter the building.

e) Vent terminal opening must be beyond any combustible overhang.

f) If condensation in the flue is a problem, the flue length should be shortened or insulated.

g) For vent specifications all of the following conditions must be met:

1) Maximum total vent length allowed in fort-five (45’) feet.

2) Maximum outside air supply duct allowed forty-five (45’) feet.

3) Maximum total vent length plus outside air supply length plus extension package shall not exceed sixty-five (65’) feet.

4) Under length conditions 1) through 3) above -- a total of two (2) elbows are allowed for vent and outside air supply together. Substract fifteen (15’) feet per additional elbow from maximum length allowed if more than two (2) elbows are used.

18677 Rev. A 8/05



Alternative Arrangements / Optional Equipment for Venting

Unvented Operation

Horizontal Venting

Vertical Venting

Draft Hood Venting

Common Venting

Outside Air Supply

a) Sufficient ventilation must be provided in the amount of 4 CFM per 1,000

BTU/hr. firing rate.

b) Refer to ANSI Z223.1 - latest revision, NPFA-54 and local codes for additional information.

c) Use of optional outside combustion air is not recommended with unvented heaters due to pressure considerations.

a) In combustible or noncombustible walls, use Tjerland VH1-4” (Stk #19022).

Follow vent manufacturer’s instructions for proper installation. (Alternative vent Enerco Stk. #19023) b) Four (4”) inch O.D. flue pipe is required. Thirty (30’) feet maximum length is recommended. Up to forty-five (45’) feet maximum may be used if insulated to prevent excess condensation. (See General Requirements on page 21 for additional information.

c) All flue joints should be sealed using suitable product such as General Electric

RTV106 or Permatex Form-A-Gasket Red High Temperature Silicone Adhesive Sealant.

d) Vent terminal should be installed at a height sufficient to prevent blockage by snow.

e) Building materials should be protected from degradation by flue gases.

a) Four (4”) inch O.D. flue pipe, maximum forty-five (45’) feet in length may be used as shown with approved vent cap. (See General Requirements on page 21 for additional information).

b) An insulated thimble may be required to pass through combustible structures

(check local codes).

c) All flue joints should be sealed using suitable products (see recommendation for horizontal venting).

a) Refer to ANSI Z223.1 - latest revision, NPFA-54 for heights and vent sizes recommended for proper venting. (Check local codes for additional information) b) Minimum six (6”) inch O.D. vent is recommended.

a) Horizontal run to vent must never exceed 75% of the vertical height of the vent.

Refer to ANSI Z223.1 - latest revision, NPFA-54 for proper vent sizes and installation.

b) Open area of common vent must equal the sum of the open area of individual vents connected to it. (See chart and diagrams - page 25).

c) Use double wall vent as required (check codes).

d) Heaters sharing a common vent must be controlled by the same thermostat.

e) All joints must be sealed using suitable products (see recommendation for horizontal vent - page 24).

f) Connections to common stack must be positioned to avoid direct opposition between streams of combustion gases.

a) See procedure and diagram on page 26.

18677 Rev. A 8/05



22

23 Section 5

Vent / Ducting

FIGURE 12: Unvented Operation

FIGURE 13a: Single Wall

Single wall vent run

Single wall terminal end

1) Ventilation equal to 4 CFM per 1,000

BTU/hr. firing rate must be provided in unvented heater installations.

2) For dimensions A “unvented” refer to

(Figure 1 -- Minimum Clearances to

Combustibles).

FIGURE 13b: Double Wall

Double wall vent rund and

Double wall terminal end

18677 Rev. A 8/05



FIGURE 14: Vertical Venting

24

THIS SPACE IS INTENTIONALLY BLANK



18677 Rev. A 8/05

25 Section 5

Vent / Ducting

FIGURE 15: Common Roof Venting

COMMON VENTING - (2) Heaters

Model# H = 6 ft.

H = 8 ft.

H = 15ft.

ERXL-60

ERXL-80

D = 7”

D = 8”

D = 6”

D = 7”

D = 6”

D = 6”

ERXL-100

ERXL-125

ERXL-150

ERXL-175

D = 8”

D = 10”

D = 10”

D = 10”

D = 8”

D = 10”

D = 10”

D = 10”

D = 7”

D = 8”

D = 8”

D = 8”

COMMON VENTING - (4) Heaters

Model# H = 6 ft.

H = 8 ft.

H = 15ft.

ERXL-60

ERXL-80

D = 10”

D = 10”

D = 10”

D = 10”

D = 8”

D = 10”

ERXL-100

ERXL-125

ERXL-150

ERXL-175

N/A

N/A

N/A

N/A

D = 12” D = 10”

D = 12” D = 10”

N/A

N/A

D = 12”

D = 12”

18677 Rev. A 8/05



16

Outside Combustible Air supply

The Ener-Radiant XL heater is approved for installation with an outside air supply system. Some compounds such as halogenated hydrocarbons or other corrosive chemicals in the air can be drawn into the equipment and cause an accelerated rate of corrosion of some of the heater components. The use of such chemical compounds near the enclosure should be avoided.

IMPORTANT: If the building has a slight negative pressure or contaminants are present in the air, on outside combustible air supply to the heaters is strongly recommended.

For an outside air supply, a four (4”) inch O.D. single wall pipe may be attached to the heater. The duct may be up to forty-five (45’) ft. maximum length or two (2’) ft. minimum length with no more than two (2) elbows. (See General Requirements on page 21 for additional information). An outside air supply should not be used with the draft hood venting configuration.

The air supply duct may have to be insulated to prevent condensation on the outer surface. The outside air terminal should be securely fastened to the outside wall by drilling four (4) 1/4” diameter holes in the outside flange; wood screws or bolts and expansion sleeves may be used to fasten terminal.

FIGURE 16: Non-Pressurized Outside Air Supply Duct

Outside Air Terminal: Use ACME #104 Enerco Stk. #19030

PCV Pipe, “Dryer Hose”, or equivalent may be used instead of standard vent pipe

18677 Rev. A 8/05



27 Section 6

Gas Piping

GAS PIPING

Section 6

Read applicable warnings in (Section 1) before proceeding with Gas Pipe installation. Improper installation may result in property damage, severe injury or death.

Meter and service must be large enough to handle all the burners being installed plus any other connected load. the gas line which feed the system must be large enough to supply the required gas with a maximum pressure drop of 1/2” water column. When gas piping is not included in the layout drawing, the local gas supplier will usually help in planning the gas piping.

A 1/2” tapping at each burner location must be located and oriented as shown in (Figure 17). To check system pressure, put a plugged 1/8” NPT tapping in the gas line at the connection to the burner farthest from the supply. Before connecting the burners to the supply system, verify that all high pressure testing of the gas piping has been complete. Do not high pressure test the gas

piping with the burners connected.

Follow these instructions to ensure a professional gas supply installation:

•

Support all gas piping with suitable pipe hanging materials.

•

Use wrought iron or wrought steel pipe and malleable iron fitting. All pipe fittings should be new and free from defects. Carefully ream pipe and tubing ends to remove obstructions and burrs.

•

Use L.P. gas-resistant joint compound on all pipe threads.

•

Check the pipe and tubing ends for leaks before placing heating equipment into service. When checking for gas leaks, use soap and water solution: NEVER USE AN OPEN FLAME.

Install the flex gas connector as shown. The flex gas connector accommodates expansion of the heating system and allows for easy installation and service of the burner.

FIGURE 17: Gas Line Connection with Stainless Steel Flex Gas Connector

18677 Rev. A 8/05



Section 7

Wiring

WIRING

Section 7

Heaters are normally controlled by thermostats. Line voltage thermostats are wired directly ( see

Feigure 18a), the recommended 24V thermostats use a relay (see Figure 18b). Heaters must be grounded in accordance with the National Electrical Code ANSI/NFPA-70 - latest revision. Heaters may also be controlled with a manual line voltage switch or timer switch in place of the thermostat.

28

FIGURE 18A: Line Voltage Thermostat Wiring

FIGURE 18b: Low Line Voltage Thermostat Wiring.



18677 Rev. A 8/05

29 Section 7

Wiring

FIGURE 19: Wiring of Low Voltage Thermostat and Relay

When usung 1 - 2 burners, use SPDT Transformer Relay / Stk. #00172

When using 3 - 4 burners, use DPDT Transformer Relay / Stk. #00183

Wires marked with an asterisk (*) are for use only with the DPDT Transformer Relay.



18677 Rev. A 8/05

FIGURE 20: Ener-Radiant XL Burner Internal Wiring

Section 7

Wiring

30

•

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105 o C and 600 volts.

•

Each burner must be electrically grounded in accordance with the National Electrical

Code ANSI / NFPA-70 - latest revision.

18677 Rev. A 8/05



31 Section 7

Wiring

FIGURE 21: Ener-Radiant XL Burner Internal Wiring Ladder Diagram



18677 Rev. A 8/05

Section 8 32

OPERATION & MAINTENANCE

Section 8

Sequence of Operation

1. Turn the thermostat up. When the thermostat calls for heat, blower motor will energize.

2. When the motor approaches nominal running RPM, the air proving switch closes and activates the ignition module.

3. The ignition module then energizes the hot surface igniter for a timed warm-up period

(approximately 45 to 60 seconds).

4. After the warm-up period, the gas valve is energized.

5. During the last part of the sequence, the igniter is de-energized and its converted to a flame sensing rod.

6. If a flame is detected, the gas valve remains open. When the call for heat is satisfied, and the system control mechanism de-energizes the burner line voltage supply, the gas valves are turned off.

7. If no flame is detected on a single-try module, the gas valve is closed, and the module will lockout until it is reset. Reset is accomplished by removing power from the module for at least five (5) seconds (thermostat cycle required).

8. If no flame is detected on a three-trial module, the gas valve is closed, and a purge period begins. After the purge, the module acts to power the igniter for a second warm-up period, and a second trial for ignition period. If flame is still not established, a third and final purge, warm-up, and trial cycle begins. After three trials, the module will lockout until reset. Reset is accomplished by removing power from the module for at least (5) seconds (thermostat cycle required).

9. On a three-trail module, if flame is established and lost on the first or second trail, the gas valve is turned off, a purge warm-up, and trail for ignition will occur on a three-trail module, only three trails for ignition are allowed per thermostat cycle.

Maintenance

For best performance, the following maintenance procedure should be performed before each heating season:

1. Be sure gas and electrical supply to heater are off before performing any service or

maintenance.

2. Check condition of blower scroll and motor. Dirt and dust may be blown out with compressed air, or a vacuum cleaner may be used.

3. Check condition of burner. Carefully remove any dust or debris from inside the burner box or burner cup.

4. Inspect the igniter. Replace igniter if there is excessive carbon residue, erosion, breakage or other defects.

5. Check the inside of the firing tube with a flashlight. If carbon or scale are present, scrape out the deposits with a wire brush or rod, or metal plate attached to a wooden pole.

6. Check to see that the burner observation window is clean and free of cracks or holes. Clean or replace as necessary.

7. Check the flue pipe for soot or dirt. After cleaning as necessary, re-attach the flue pipe to heater.

8. Outside surfaces of heater may be cleaned by wiping with a damp cloth.

9. A qualified service agency should be contacted for service other than routine maintenance.

10. Check vent terminal and fresh air inlet to see that they have not become blocked during the non-hearing season. If either pipe is restricted, the air switch won’t close, resulting in a no-heat situation.

18677 Rev. A 8/05



33 Section 8

Operation & Maintenance

Troubleshooting

Blower Motor

Fails to Run:

Igniter

Does Not Glow:

Valve Does Not

Come On:

Burner Does Not

Light:

Burner Does Not

Stay Lit:

CAUTION: Before opening the Ener-Radiant XL burner door for any type of service, be sure the gas supply has been shut off at the heater and the electrical cord from the burner box has been unplugged.

1. Is the thermostat calling for heat? Is there 115V at the burner receptacle?

2. Check blower side door for seal. Check door switch. Replace if necessary.

3. Check blower for obstructions. Replace blower if necessary.

1. Check igniter for damage. Replace if necessary.

2. Check voltage and resistance at igniter.

(Voltage should be 115V. Resistance should be 40-75 ohms).

3. Check for obstruction to the air inlet and outlet.

4. Check wiring and hose connections to the air switch. Replace if necessary.

5. Check voltages at transformer primary and secondary. Replace transformer or module if necessary.

Gas pressure downstream of gas control cab be measured by using a manometer and connecting to pressure tap on control.

1. Check to see if manual valve heater is ON.

2. Check to see if manual valve knob on heater gas control is ON.

3. Supply gas pressure can be checked at 1/8” NPT pressure tapping on heater external manual valve.

4. Check to see if gas control is opening: no manifold pressure indicates valve closed.

If the vale is closed, either the gas valve is closed or the ignition is faulty.

WARNING: do not disconnect ground leads inside heater. Do not interchange grounded and ungrounded leads on transformer or ignition module.

1. Check to see if gas lines were properly purged of air.

2. Check inlet and outlet pressure during ignition period.

Natural inlet pressure should be 4.6”

Natural outlet pressure should be 3.5”

LP inlet pressure should be 11.0”

LP outlet pressure should be 10.5”

3. Check for proper orifice and air plate.

1. Check ground wire continuity.

2. Check burner internal wiring for reversed leads.

3. Check insulation on the igniter leads.

4. Replace module if necessary.

18677 Rev. A 8/05



Section 8

Honeywell Valve LED Status

The ENER-Radiant XL series Tube Heater is equipped with a honeywell Smart Valve. This valve has a built-in diagnostic program, which will assist in troubleshooting in the event of a valve-related problem. The LED or (Light

Emitting Diode) is located on the top of the valve as shown in diagram below. The LED status indications are listed below to help with troubleshooting

FIGURE 22:

34

Off

Off

Bright-Dim

2-Flashes

3-Flashes

4-Flashes

5-Flashes

6-Flashes



INDICATED

No power to the control

Normal operation

This indication shows whenever the system is powered, unless some abnormal event has occurred.

Airflow providing switch remains closed longer that

30 seconds after call for heat begins (air proving switch stuck closed).

Airflow providing switch remains open longer that 30 seconds after combustion air blower is energized-or blower does not energize.

White jumper wire is loose

Flame signal sensed out of proper sequence.

system Lockout.

18677 Rev. A 8/05

35 Section 8

Operation & Maintenance



18677 Rev. A 8/05

Section 8 36



18677 Rev. A 8/05

37 Section 9

Appendices

APPENDIX I: Replacement Parts.

4

5

6

7

8

9

10

11

Item

1

2

3

Part Number

02731

02730

10413A

10414A

01391A

02371

07376

17376

00016

00017

12404

08364A

02729

Description

Hot Surface Igniter

Flame Sensor

Air Sensing Switch (ERXL-60, 80, 100, 125)

Air Sensing Switch (ERXL-150, 175)

Door Switch

Burner Cup Assembly

Motor and Blower Assembly

Manifold

Gas Valve-Natural Gas

Gas Valve-Lp gas

Inspection Window

Transformer

Tube Flange Casting

Section 9



18677 Rev. A 8/05

FIGURE 24: Ener-Radiant XL Burner & Control Housing

Section 9

Appendices

38



18677 Rev. A 8/05

39 Section 9

Appendices

APPENDIX II:

Section 9

Engineering Specifications

The total heating system supplied shall be design certified by the American Gas Association and the

Canadian Gas Association.

A. Burner & Burner Controls

1. Burners shall be capable of firing with one of the fuel options as specified on the purchase documents: Natural Gas or LP.

2 Burners shall be supplied to fire at any one of the input rates as specified.

ERXL-60 60,00 BTU/hr

ERXL-80 80,000 BTU/hr

ERXL-100 100,000BTU/hr

ERXL-125

ERXL-150

ERXL-175

125,000 BTU/hr

150,000 BTU/hr

175,000 BTU/hr

3. Burner shall be equipped with a direct sense silicon-carbide hot surface ignition control system with 100% shut-off ignition device. Power supplied to each heater shall be 120V, 60HZ, single phase. Burners shall be rated for 1.0 Amp (run) and 5.0 Amp (start).

4. Burner shall be equipped with thermal overload motor protection, balanced air rotor, combustion air proving safety pressure switch, and viewing window for flame obsevation.

5. When specified, in contaminated environments, the burner shall be capableof supplying outside air tp each burner for the support of combustion.

6. All burners shall be pre-wired with a grounded electrical cord and plug.

7. At customer’s choice, burners may be controlled with either an optional line voltage thermostat or by optional low voltage thermostats with an appropriate low voltage transformer relay.

8. Gas supply to the burner shall conform to the following:

1/2” NPT gas connector size

Natural Gas:

4.6” W.C. MIN, 14.0” W.C. MAX

LP Gas:

11” W.C. MIN, 14.0” W.C. MAX

B. Heat Exchanger

1. Radiant tubing shall be 4” diameter aluminized steel supplied in 10 ft. Sections. Sections shall be joined with stainless wrap-around couplings.

2. Reflector to be of aluminum material and designed to direct all radiant output below horizontal centerline of radiant tube.

3. Heaters shall be vented according to manufacturer’s recommendations.

18677 Rev. A 8/05



Section 9

Appendices

APPENDIX II:

General Specifications for

Ener-Radiant XL ERXL-Series Heaters

Burner Ratings and Heat Exchanger Lenghts

(Natural an LP)

Model# Rate (BTU/hr.) Heat Exchanger Length Turbulator

ERXL-60

ERXL-80S

60,000

80,000

ERXL-80 80,000

ERXL-100S 100,000

ERXL-100 100,000

ERXL-125S 125,000

ERXL-125

ERXL-150

125,000

150,000

ERXL-150L 150,000

ERXL-175 175,000

ERXL-175L 175,000

20 ft.

20 ft.

30 ft.

30 ft.

40 ft.

40 ft.

50 ft.

50 ft.

60 ft.

50 ft.

60 ft.

10 ft.

10 ft.

10 ft.

5 ft.

None

None

None

None

None

None

None

FIGURE 25:

Section 9

Gas pressure at MANIFOLD

Natural Gas: 3.5” W.C.

LP Gas: 10.5” W.C.

1/2” NPT Gas Connector Size

Gas INLET pressure

Natural gas: 4.6” W.C. Min

LP Gas:

11.0” W.C. Max

11.0” W.C. Min

14.0” W.C. Max

1/2” NPT Gas Connector Size

Electrical Rating: (All Models)

120V-60Hz

1.0 AMP (Run) 5.0 AMP (Start)

Dimensions:

Flue Connection Size: 4”

Outside Air Connection Size 4”

Ener-Radiant XL Dimensions & Suggested Mounting Heights

40



18677 Rev. A 8/05

Section



18677 Rev. A 8/05

Section



Enerco Technical Products, Inc.

4560 W.160th St.Cleveland, Ohio 44135

Phone: 800-251-0001 www.enerco.com

18677 Rev. A 8/05

INST INSTALLA ALLA ALLATION and OPERA

WARNING

FIRE OR EXPLOSION HAZARD

Can cause property damage, severe injury or death.

WARRANTY

WARNING

FAILURE TO FOLLOW THESE

INSTRUCTIONS CAN CAUSE PROPERTY

DAMAGE, SEVERE INJURY OR DEATH:

IMPORTANT

FAILURE TO FOLLOW THESE

INSTRUCTIONS CAN CAUSE PROPERTY

DAMAGE OR PERSONAL INJURY

CAUTION

FAILURE TO FOLLOW THESE

INSTRUCTIONS CAN CAUSE DAMAGE, TO

THE SYSTEM COMPONENTS

WARNINGS & WARRANTY

INDEX

INTRODUCTION

INSTALLATION: Planning

INSTALLATION: Assembly

INSTALLATION: Venting & Ducting

INSTALLATION: Gas Piping

INSTALLATION: Wiring

OPERATION/MAINTENANCE

APPENDICES

1 1-3

2

3

4

5

6-14

4 15-20

5 21-26

6

7

8

9

27

28-31

32-36

37-40

INTRODUCTION

Section 2

Checking Shipment

Installer Responsibility

PLANNING

Section 3

National Standards and Applicable Codes

Critical Considerations

Installation Procedure

Stock Number

ACCESSORY PARTS LIST

Description

Clearances To Combustibles

WARNING

FIRE OR EXPLOSION HAZARD

Can cause property damage, severe injury or death.

Clearances To Combustibles

Parts List for Packaged Ener-Radiant XL Tube Heaters

Parts List for Packaged Ener-Radiant XL Tube Heaters

INSTALLATION & ASSEMBLY

Section 4

FIGURE 3: Coupling Assembly

FIGURE 4: Installation of Elbow & Coupling (optional equipment)

FIGURE 5: Typical Suspension Details

FIGURE 6: Tube & reflector Hanger

FIGURE 7: Mounting Flange / Tube Detail

FIGURE 8: Burner Box / Transition Tube Detail

VENTING / DUCTING

Section 5

General Requirements

Alternative Arrangements / Optional Equipment for Venting

FIGURE 12: Unvented Operation

FIGURE 14: Vertical Venting

FIGURE 15: Common Roof Venting

Outside Combustible Air supply

FIGURE 16: Non-Pressurized Outside Air Supply Duct

GAS PIPING