Detroit Radiant Products HL2 Series Installation, Operation, Maintenance And Parts Manual

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Detroit Radiant Products HL2 Series Installation, Operation, Maintenance And Parts Manual | Manualzz
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual*
! WARNING: This heater must be installed and serviced by trained gas installation and service personnel only!
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
Protect yourself and others by observing all safety information. Retain instructions for future reference.
*For complete installation instructions, see the General Manual that accompanied this piece.
Additional literature on this and other products are available at www.reverberray.com.
HL2 Series
Project: _________________________ Date: _______________
Customer Name: _______________________________________
Location: _____________________________________________
City: ______________________ State: _______ Zip: __________
Contractor: ____________________________________________
Engineer: _____________________________________________
Address: _____________________________________________
City: ______________________ State: _______ Zip: _________
Serial #: _________________________ Phone#: _____________
Local Representative: ___________________________________
Date of Installation: ______________________________________
Notes: _______________________________________________
Models
Mode l #
HL2 20-65
HL2 20-75
HL2 20-100
HL2 30-65
HL2 30-75
HL2 30-100
HL2 30-125
HL2 40-65
HL2 40-75
HL2 40-100
HL2 40-125
HL2 40-150
HL2 40-175
HL2 50-125
HL2 50-150
HL2 50-175
HL2 50-200
HL2 60-150
HL2 60-175
HL2 60-200
HL2 70-175
HL2 70-200
(cir cle one )
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
Page
Models
1
Warnings
2
Clearances to Combustibles 2
Product Summary
3
Product Instructions
3
Heater Requirements
4
Theory of Operation
4
Wiring Diagrams
5-7
Flowchart
8-9
Parts Listing
10-11
V.6/03
Ga s Type
Qty.
Table of Contents
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
LP
MBTU's
65 / 50
75 / 50
96 / 65
65 / 50
75 / 50
100 / 65
125 / 95
65 / 50
75 / 50
100 / 65
125 / 95
150 / 100
175 / 125
125 / 95
150 / 100
175 / 125
200 / 145
150 / 100
175 / 125
200 / 145
175 / 125
200 / 145
Stra ight
Le ngth
21'-7'
21'-7'
21'-7'
31'-3'
31'-3'
31'-3'
31'-3'
40'-11'
40'-11'
40'-11'
40'-11'
40'-11'
40'-11'
50'-7'
50'-7'
50'-7'
50'-7'
60'-3'
60'-3'
60'-3'
69'-11"
69'-11"
U-Tube
Le ngth W e ight
13'-0"
120 #
13'-0"
120 #
13'-0"
120 #
*17'-8"
160 #
*17'-8"
160 #
*17'-8"
160 #
*17'-8"
160 #
22'-8"
190 #
22'-8"
190 #
22'-8"
190 #
22'-8"
190 #
22'-8"
190 #
22'-8"
190 #
*27'-4"
235 #
*27'-4"
235 #
*27'-4"
235 #
*27'-4"
235 #
32'-4"
265 #
32'-4"
265 #
32'-4"
265 #
*37'-2"
300 #
*37'-2"
300 #
Typica l
Mount
He ight
9'-14'
10' - 15'
11' - 18'
10' - 15'
11' - 18'
12' - 20'
13' - 23'
11' - 18'
11' - 18'
12' - 20'
13' - 23'
14' - 25'
15' - 27'
15' - 27'
15' - 27'
16' - 30'
17' - 35'
16' - 30'
16' - 30'
17' - 35'
19' - 42'
19' - 42'
Com bustion
Cha m be r
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Aluminized
Titanium Coated
Titanium Coated
Aluminized
Titanium Coated
Titanium Coated
Titanium Coated
Titanium Coated
Titanium Coated
Titanium Coated
Titanium Coated
Titanium Coated
* Model requires 5EA-SUB accessory package.
Ra dia nt
"Type " Tube "Type " Tube Ba ffle
Em itte r Tube
Pkg #1
Pkg. #2
Pie ce s
4" Aluminized
20-4 Alum
N/A
5
4" Aluminized
20-4 Alum
N/A
5
4" Aluminized
20-4 Alum
N/A
5
4" Aluminized
30-4 Alum
N/A
4
4" Aluminized
30-4 Alum
N/A
4
4" Aluminized
30-4 Alum
N/A
5
4" Aluminized
30-4 Alum
N/A
5
4" Aluminized
40-4 Alum
N/A
2
4" Aluminized
40-4 Alum
N/A
2
4" Aluminized
40-4 Alum
N/A
4
4" Aluminized
40-4 Alum
N/A
4
4" Aluminized
40-4 Titan
N/A
4
4" Aluminized
40-4 Titan
N/A
4
4" Aluminized
40-4 Alum
10-4 Alum
4
4" Aluminized
40-4 Titan
10-4 Alum
4
4" Aluminized
40-4 Titan
10-4 Alum
2
4" Aluminized
40-4 Titan
10-4 Alum
2
4" Aluminized
40-4 Titan
20-4 Alum
2
4" Aluminized
40-4 Titan
20-4 Alum
2
4" Aluminized
40-4 Titan
20-4 Alum
2
4" Aluminized
40-4 Titan
30-4 Alum
2
4" Aluminized
40-4 Titan
30-4 Alum
2
Warranty registration options:
1. Register online at www.reverberray.com/warranty
2. Complete this page and fax to Detroit Radiant Products Co.
3. Complete this page and mail to Detroit Radiant Products Co.
Printed in U.S.A.
© 2002 Detroit Radiant Products Co.
21400 Hoover Rd., Warren, MI 48089
T. (586) 756-0950 F. (586) 756-2626
Form# LIOHL2-3M-10/03 (ID)
Replaces Form# LIOHL2-3M-12/02
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
HL2 Series
HL2 Series Mechanical Instructions
! WARNING!
NOT FOR RESIDENTIAL USE!
Do not use in the home, sleeping quarters,
attached garages, etc.
!
WARNING!
This heater must be installed and serviced by
trained gas installation and service personnel
only. Read and understand these instructions
thoroughly before attempting to install, operate
or service this heater. Failure to comply could
result in personal injury, asphyxiation, death,
fire, and/or property damage. Retain these
instructions for future reference.
!
WARNING!
This is not an explosion-proof heater. Where
there is the possibility of exposure to flammable
vapors, consult the local fire marshal, the fire
insurance carrier and other authorities for
approval of the proposed installation.
!
WARNING!
Failure to comply with the stated clearances
to combustibles could result in personal injury,
death and/or property damage.
!
MOUNTING
ANGLE
0º
HL2 (20,30,40) - 65, 75 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
0º
HL2 (20,30,40) - 100 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
0º
HL2 (30,40,50) -125 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
0º
HL2 (40,50,60) - 150 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
0º
HL2 (40,50,60,70) - 175 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
0º
HL2 (50,60,70) - 200 [N,P]
45º
W/1 side shield
0º
W/2 side shields
0º
20 ft from burner
0º
MODEL NO.
WARNING!
This heater should be installed so that the
minimum clearances to vehicles, as marked
on the heater, will be maintained. If vehicle
lifts are present, ensure that these clearances
will be maintained from the highest raised
vehicle.
SIDE
FRONT BEHIND
9
9
39
8
29
8
9
9
7
7
14
14
39
8
29
8
16
16
7
7
20
20
58
8
42
8
20
20
7
7
24
24
58
8
42
8
23
23
11
11
34
34
63
8
50
8
30
30
11
11
41
41
63
8
54
8
30
30
11
11
SIDE
SIDE
TOP
BELOW
6
10
6
6
6
6
10
6
6
6
6
10
6
6
6
6
10
6
6
6
6
10
6
6
6
6
10
6
6
6
60
60
60
60
30
66
66
66
66
30
76
76
76
76
30
81
81
81
81
44
92
92
92
92
44
94
94
94
94
44
TOP
TOP
WARNING!
In locations used for the storage of combustible
materials, signs must be posted to specify the
maximum permissible stacking height to
maintain the required clearances from the
heater to the combustibles. Signs must either
be posted adjacent to the heater thermostats or
inthe absence of such thermostats, in a
conspicuous location.
!
CLEARANCES TO COMBUSTIBLES (IN.)
FRONT
BEHIND
BELOW
BELOW
0 MOUNTING ANGLE
0 W/1 SIDE SHIELD
TOP
TOP
BEHIND
FRONT
SIDE
SIDE
BELOW
BELOW
45 MOUNTING ANGLE
0 W/2 SIDE SHIELDS
2
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
HL2 Series Mechanical Instructions
This supplement is designed to address the specifics of the HL2 Series - see page 12 for product features.
Product Summary
HL2 Series heaters are available from 20 to 70 foot, 65,000 to 200,000 BTU’s, natural or LP gas. HL2
Series are positive pressure, two-stage heaters that feature aluminized steel for it’s radiant pipes.
Operational Features
HL2 Series heaters require a 24 Volt, two-stage thermostat to operate. Each heater has a round terminal
strip (or yellow cord) that accepts three 1/4 in. insulated spade terminals for the thermostat wiring. Do not
install 120V to this 24V connection.
There are two versions of the HL2 Series. The standard version comes without a relay board (HLRB) and
the other is supplied with a relay board (HLRB) installed. A HL2 Series unit without a relay board (HLRB)
supplies it’s own control voltage and is identified by the white band located around the terminal plug. If units
are common vented or if two or more models are to be controlled by a single thermostat, they must be
factory assembled with relay boards (HLRB) and installed using an external transformer (field supplied) as
shown on page 6. A HL2 Series unit with a relay board (HLRB) installed is identified by the orange band
around the terminal strip.
On stainless steel heaters, units with a relay board (HLRB) will be labeled accordingly. All models assembled
with a HLRB reference the suffix “D” on the AGA rating plate.
Specific Mechanical Instructions
Be sure to indentify the titanium coated combustion chamber (150-200 MBTU/H) and place as the first tube
section directly following the burner box. The identification sticker found on the swagged end of the tubing
will identify the titanium coated combustion tube.
175,000 and 200,000 BTU/H Models must be installed with a stainless steel tube clamp at the second joint
of the exchanger between the first and second radiant tubes.
Note baffle quantities for your model and place baffles in the last tubes (farthest from the burner) as shown
on pages 13-14 of the general manual, and below (*).
Tube Installation Sequence
Aluminized
(50-100 MBTU/H)
B
B = Burner Location
Aluminized
* Baffle Location
*
Aluminized
(50-125 MBTU/H)
Aluminized
B
*
Aluminized or Titanium
(50-125 MBTU/H)
Aluminized
(150-175 MBTU/H)
Aluminized
Aluminized
B
*
Aluminized or Titanium
(50-125 MBTU/H)
Aluminized
(150-200 MBTU/H)
Aluminized
Aluminized
Aluminized
B
*
Aluminized or Titanium
(50-125 MBTU/H)
Aluminized
(150-200 MBTU/H)
Aluminized
Aluminized
Aluminized
Aluminized
B
*
Aluminized or Titanium
(50-125 MBTU/H)
Aluminized
(150-200 MBTU/H)
Aluminized
Aluminized
Aluminized
B
Aluminized
Aluminized
Aluminized
*
3
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
HL2 Series
Electrical Requirements
First Stage Running Circuit:
♦
♦
♦
♦
After ignition the flame-rod monitors the main burner flame. If
flame is lost, the control acts to close the gas valve within one
second and a new trial sequence, identical to the start up
sequence, is initiated. If proof is not established within 8.5
seconds, the unit will retry 2 additional ignition sequences and
then proceed to hard lock-out. The control can be reset by
interrupting the power source or at the thermostat.
120 Volt - 60 Hz GRD, 3-wire.
24V thermostat connection.
Starting current 4.8 amps
Running current 1.1 amps
Gas Requirements
Second Stage Running Circuit:
♦ Manifold Pressure
♦
♦
Stage two on the gas valve is powered directly from the second
stage of the thermostat. In order for the second stage to flow
the higher output, the first stage has to be energized as well.
The thermostat will determine which stage is required to maintain
the desired comfort level.
• Nat. 3.5’’ • LP. 10.0’’
Minimum Inlet Pressure
• Nat. 5.0’’ • LP. 11.0’’
Maximum Inlet
• Nat. 14.0’’ • LP. 14.0’’
Shut Down:
Ventilation Requirements
When the thermostat is satisfied the fan will enter into a 2
minute post-purge cycle.
♦ Consult the general manual for venting instructions.
Soft Lockout:
In the event of an external interruption (wind, gas, etc.) the
heater will go into a “soft-lockout” feature. In this mode the
heater will attempt a normal start-up after approximately 15
minutes. In the event of continued problems, the heater will go
into a hard lock-out mode.
♦ For unvented operation, there must be a positive air
displacement of at least 4.0 CFM per 1000 BTU/H for natural
gas or 4.5 CFM per 1000 BTU/H for LP gas. WVE-4
termination cap must also be used.
Lockout Codes:
In event of a component failure, a red LED diagnostic light
located on the burner box end panel will flash a code identifying
the fault. Lockout codes are summarized in the table below.
Some fault codes have a time delay before the LED will flash.
Refer to the FAULT CODE DELAY on the chart to see the
approximate time delay.
Theory of Operation
Standby:
The Micro 60U24 control continually checks for internal faults,
safety circuit integrity, and relay contact positioning.
Starting Circuit:
Upon a call for heat, the control will verify that the differential
safety pressure switch is in the proper position. The fan relay
energizes the fan, an operational static pressure is achieved
and the normally open differential pressure switch will close,
initiating the ignition sequence. The glow-bar is powered and
after 45 seconds the main gas valve opens. If flame is not
established the heater will attempt to re-ignite for a total of
three trials for ignition and then proceed to lockout.
LED CODE
FAULT STATUS
FAULT CODE DELAY
Initial flash on power up,
then steady off
Normal operation
Immediate
Steady on
Module failure / Internal fault
Immediate
1 flash
Ignition failure
30-32 minutes
2 or 3 flashes
APS - Note: fan / intake / exhaust
10-12 minutes
4 flashes
Solenoid valve fault / Leaky valve /
Flame amplifier fault
Immediate
No flash on 117V start up
Transformer fault
Immediate
Note: Hard lockout LED CODE will appear upon completion
of the soft lockout sequence of operation.
4
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
Internal Wiring Diagrams
MICRO 60U-24
MICRO 60U-24 LADDER DIAGRAM
L1
120VAC
L2
120V
TRANSFORMER
24V
IGNITOR
PRESSURE SWITCH
T'STAT
TERMINAL
APS1
BLOWER
HSI
FAN
117L
GND
TH
24V
GND
VALVE
APS2
APS1
APS1
APS2
117N
117N
HSI
INDICATOR
LIGHTS
GND
PROBE
2-STAGE T'STAT
(FIELD SUPPLIED)
FLAME
ROD
MICRO 60U-24
IGNITION
MODULE
GAS VALVE
STATUS
LIGHT
(FIELD SUPPLIED)
LLWT38
MICRO 60U-24 BLOCK DIAGRAM
T'STAT
TERMINAL
2-STAGE T'STAT
(FIELD SUPPLIED)
APS1 (NO)
PRESSURE SWITCH
INDICATOR
LIGHTS
STATUS
LIGHT
TRANSFORMER
FLAME
ROD
MICRO 60U-24
IGNITION MODULE
IGNITOR
L1
120VAC
L2
GAS VALVE
BLOWER
NO
OFF
(FIELD SUPPLIED)
5
LLWT38
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
HL2 Series
Field Wiring Diagrams
Note: If optional yellow control cord is installed then the
following wire colors apply:
24v - Green
Low - White
High - Black
White label
PANEL GROUND
24V 1
1/4 spade terminals
required - field
supplied
LO HI
24v
N
Low
High
Note: If optional Black power
cord is installed then L1 is
Brown or Black and L2 is Blue
or White.
2
Ground Screw
on Burner Box
HL2 HEATER
BURNER BOX
T-stat
L1
Additional wire needed on thermostats that
require constant power.
L2
120 Volt Power
(Observe Polarity)
Single heater, single thermostat, no relay board (white label).
Orange
label
1/4 spade terminals required
- field supplied
PANEL GROUND
N
1
2
LO HI
24v
N
Low
Orange
label
High
PANEL GROUND
N
24V
T-stat
Additional wire needed on thermostats that
require constant power.
HL2 HEATER
BURNER BOX
1
2
LO HI
HL2 HEATER
BURNER BOX
120 V
Orange
label
PANEL GROUND
N
1
Note: If optional yellow control cord
is installed then the following wire
colors apply:
Neutral- Green
Low - White
High - Black
2
LO HI
EXTERNAL TRANSFORMER
-FIELD SUPPLIED
HL2 HEATER
BURNER BOX
Note: If optional Black power
cord is installed then L1 is
Brown or Black and L2 is Blue
or White.
120 Volt Power
(Observe Polarity)
L1
L2
Multiple heaters, single thermostat, with a relay board (HLRB - orange label).
6
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
Alternative Wiring Diagrams
MICRO 60U-24
WITH HLRB RELAY BOARD
MICRO 60U-24 LADDER DIAGRAM - WITH RELAY BOARD
L1
120VAC
L2
120V
HL RELAY BOARD
TRANSFORMER
24V
IGNITOR
FLAME
ROD
PRESSURE SWITCHES
T'STAT
TERMINAL
BLOWER
FAN
117L
HSI
HSI
117N
117N
APS1
APS1
APS2
APS2
24V
VALVE
TH
GND
GND
24V
GND
INDICATOR
LIGHTS
PROBE
2-STAGE T'STAT
(FIELD SUPPLIED)
MICRO 60U-24
IGNITION
MODULE
120V
120/24V
TRANSFORMER
(FIELD SUPPLIED)
GAS VALVE
STATUS
LIGHT
(FIELD SUPPLIED)
LLWT39
MICRO 60U-24 BLOCK DIAGRAM - WITH RELAY BOARD
T'STAT
TERMINAL
HL RELAY BOARD
2-STAGE T'STAT
(FIELD SUPPLIED)
APS1 (NO)
PRESSURE SWITCHES
STATUS
LIGHT
INDICATOR
LIGHTS
TRANSFORMER
FLAME
ROD
120/24V
TRANSFORMER
(FIELD SUPPLIED)
MICRO 60U-24
IGNITION MODULE
IGNITOR
L1
120VAC
L2
BLOWER
GAS VALVE
ON
OFF
(FIELD SUPPLIED)
7
LLWT39
8
YES
NO
NO
Is the ignitor
physically
damaged?
YES
YES
Is the inlet or the outlet of the unit
obstructed? I.e. ice, birds nest, dirt, etc.
NO
ignition sequence (usually 30-45
seconds after power to heater). Is it
120V?
NO
Replace bad circuit board.
NO
Is the circuit board
sending 120V to the
fan?
YES
YES
YES
NO
Find source of electrical
problem between the external
transformer and thermostat.
NO
Is there 24V to the
thermostat?
Is there 120V on the
primary side of the
internal transformer?
NO
24V wire on the circuit
board and ground on the
circuit board 24V?
NO
The thermostat or wiring is
faulty and should be
replaced or repaired.
The circuit board is
faulty and must be
replaced.
NO
YES
YES
Replace.
The fan is faulty and
must be replaced.
NO
Is the pressure switch stuck
in the closed position.
NO
Is the fan obstructed?
Shaded
b o x e s
indicate
troubleshooting
for heaters with
Relay
Boards
(HLRB) installed.
YES
Is the circuit
board sending
120V to the fan?
The internal
transformer is
faulty and must be
replaced.
*
NO
YES
Correct wiring.
The circuit board
is faulty and must
be replaced.
Remove
obstruction.
The relay board is faulty
and must be replaced.
NO
Is the power across the TH
wire on the circuit board
and ground on the circuit
board 24V?
YES
Thermostat or wiring from
thermostat to heater is faulty
and must be replaced.
NO
YES
Replace
Switch.
YES
Is there 24V
across the TH
and ground
terminals on
the circuit
board?
Remove obstruction.
Is the power across the middle
(low) terminal (on the TP213-24V plug) and ground (a
screw on the burner box) 24V?
The fan is faulty and
must be replaced.
Repair wiring or hose
connections.
NO
YES
Is the power across the YES
YES
Is the pressure switch stuck
in the closed position.
Is the fan obstructed?
NO
Repair the wiring between the
transformer and the TP-213-24V
plug.
Transformer is faulty and
must be replaced.
NO
side of transformer?
Check for loose wiring or restrictions in
hose connections to the pressure switch.
Are they ok?
Is the resistance
through the ignitor
45-400 ohms?
NO
YES
Is there 24V on the
secondary side of the
external transformer?
Replace ignitor.
NO
YES
Is there 120V on the primary side
of the external transformer?
NO
YES
Circuit board is faulty and
must be replaced.
NO
YES
YES Is there 24V on secondary YES
Is there 120V on the
primary side of the
transformer?
NO
Is the power across the
left terminal (on the TP213-24V plug) and ground
(a screw on the burner
box) 24V?
HL2 V.6/03 Troubleshooting Flow Chart
Is the power across the
left and center terminal
on the TP-213-24V plug
24V?
YES
NO
YES
Check voltage at ignitor during the
NO
External transformer is
faulty and must be replaced.
NO
Find the source of the
electrical problem between
panel & heater.
NO
Is the power at the
heater 120V?
YES
Does the heater have a
relay board? See page 6
of HL-2 insert for details
on how to determine if
heater has a relay board.
Find the source of the
electrical problem between
panel & external
transformer.
Does the
ignitor warm up
and glow red?
YES
Does the fan
blower turn
on?
Turn up thermostat
9
NO
NO
YES
NO
NO
Troubleshooting ends.
Replace gas
valve.
YES
YES
YES
Correct
problem.
NO
NO
Correct
problem.
YES
* Baffle(s) is in the tube(s) farthest
from the burner.
* Heater, fan blower, squirrel cage,
intake and exhaust are clean and free
from dirt and obstructions.
* The 4” air intake pipe does not
exceed 20 feet and/or 2 elbows.
* There is not a negative pressure
experienced at the area of air intake
(i.e. attic space, high-winds, very tight
building).
Replace the pressure switch after verifying the
following:
The valve is faulty
and must be replaced.
YES
YES
NO
See page 4 for fault
flash code signals.
Check to make sure
flame sensor wire is
OK and then replace
circuit board.
YES
With microammeter, check DC
voltage at flame rod. Is it greater
than 0.7 microamps?
Sensing rod is faulty or flame is
weak. Check to make sure heater
is operating at proper gas
pressure as indicated on AGA
burner rating label and then
replace sensing rod if needed.
YES
WARNING:
Bypassing any
switch is for testing
purposes only. Do
not leave switch
bypassed during
normal operation
or heater’s built-in
safety mechanisms
will be
compromised.
The relay board
is faulty and
must be replaced.
NO
Measure the voltage
across the red wire on
the relay board and
GND on the circuit
board. Is there 24V?
NOTE: To confirm the heater is not in high-fire mode, check
the manifold pressure. If 3.5” natural or 10” propane, the light
is faulty and should be replaced. If the manifold pressure ranges
from 2.3” to 2.8” Natural (model dependent) and 6.0” to 7.5”
Propane (model dependent), the heater is in low-fire mode and
the troubleshooting steps described here should be followed.
Repair or replace faulty
wiring or thermostat.
NO
On the outside of the heater, check for
24V across COM and HIGH on the
TP-213-24V plug. Is there 24V?
If heater does not go into high-fire mode, check the following.
Pressure switch may
be faulty or there is
a restriction in the
exhaust.
Correct problem.
NO
Is the heater properly grounded?
Is the heater’s polarity correct?
Check to make sure that the gas pressure
is within minimum and maximum inputs
as indicated on the AGA burner rating
label. Is gas pressure OK?
YES
Does the burner
come on and then
turn off immediately
(1 or 2 seconds).
NO
YES
Check to make sure gas pressure is
within minimum and maximum inputs,
as indicated on AGA burner rating
label. Is gas pressure OK?
Correct
problem.
NO
Possibly, the circuit board
and/or wiring harness is
faulty. These should be
replaced.
Replace circuit board.
Make sure gas lines were
purged of air.
YES
Does the burner stay on for
approx. 8 seconds and then
shut off?
Is the gas cock in
the ON position?
The following can cause the heater
to shut down:
* Improper grounding
* High winds
* Taking combustion air from the attic
* Dirty environment
* Baffle improperly positioned
* Fluctuating gas pressure
YES
NO
Check to make sure gas pressure is
within minimum and maximum inputs,
as indicated on AGA burner rating
label. Is gas pressure OK?
Does heater stay on until
call for heat ends?
YES
Does the burner
stay on?
YES
Does the burner
light?
YES
After ignitor is
warmed up, does gas
valve open?
Test for 24V at valve
during valve opening
period (usually 30-45
seconds after power to
the heater). Is there 24V
to valve for 8 seconds?
Remove obstruction.
NO
After 10-12 minutes of non-operation
has passed, is there a flash code for ASP1 failure (2 or 3 flashes)?
*
* *
828
70
825
10
67
827
832
66
44
826
802
851
33B
122
31B
852
68A
55A
76
212
83
208
840
31B
841
223
804
204
NOPS
201
200
54
218
97
303A
217
1
205
5
214
202
50
19B
106
9
10
105
12
222A
20C
222
82
221
11
21B
26A
26B
tio
us
mb
o
C
26E
ha
nC
er
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21B
220
26A
26D
itte
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HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
HL2 Series
Parts Breakdown
11
TP#
TP-111
TP-112
TP-122
TP-200
TP-201
TP-202
TP-204
TP-205
TP-208
TP-212
TP-217
TP-218
TP-220
TP-221
TP-222
TP-223
TP-303A
TP-802
TP-804
TP-825
TP-826
TP-827
TP-828
TP-832
TP-840
TP-841
TP-851
TP-852
TP-NOPS
(TP-264B)
(TP-264E)
(TP-264D)
(TP-264F)
ITEM
5' ALUM. TUBE, PAINTED W/1 CLAMP
5' REFLECTOR
GASKET FOR AIR ORIFICE & AIR COLLAR
BURNER (50 TO 100 MBTU/H)
BURNER (125 MBTU/H TO 200 MBTU/H)
16" BURNER TUBE W/ FLANGE
GAS ORIFICE - CONSULT FACTORY
GLO-BAR HOLDER
"Z" MOUNTING BRACKET
1/2" X 3" PIPE NIPPLE
PRESSURE BARB FITTING
EXHAUST PRESSURE TUBE (VINYL)
STAIN. STL. TUBE CLAMP (175 & 200 MBTU/H)
GLO-BAR HOLDER GASKET
FLAME ROD
GAS MANIFOLD
END PANEL - RIGHT
END PANEL - LEFT
CONTROL BOX
OPTIONAL HLRB RELAY BOARD
40VA TRANSFORMER (OLD TP219)
RED LED DISPLAY DIAGNOSTIC LIGHT
YELLOW OPERATIONAL IND. LIGHT (OLD TP216)
THERMOSTAT TERMINAL STRIP (OLD TP213)
36E96-224 TWO STAGE GAS VALVE-NAT (OLD TP210)
36E96-226 TWO STAGE GAS VALVE-LP (OLD TP210P)
MICRO-60-24 DIAGNOSTIC CIRCUIT BOARD
WIRE HARNESS SET (3 PCS.) FOR MICRO 60 BOARD
N. O. Pressure Switch (Select Switch Below, BTU Dependent)
DIFFERENRIAL PRESSURE SWITCH - 50 TO 100 MBTU/H
DIFFERENTIAL PRESSURE SWITCH - 125 & 150 MBTU/H
DIFFERENTIAL PRESSURE SWITCH - 175 MBTU/H
DIFFERENTIAL PRESSURE SWITCH - 200 MBTU/H
HL2 SERIES PARTS LISTING
CONTROL BOX COVER
FLANGE GASKET
CONDUIT COUPLING
CONDUIT 4" X 1/2"
GLO-BAR IGNITOR BOX
GLO-BAR IGNITOR BOX COVER
SIGHT GLASS GASKET
SIGHT GLASS
SIGHT GLASS WASHER
WIRE HANGER
120" REFLECTOR
TUBE CLAMP
10 FT. ALUMINIZED RADIANT/COMBUSTION TUBE
10 FT. TITANIUM COATED COMBUSTION TUBE
10 FT. 304 STAINLESS RADIANT TUBE
10 FT. 409 STAINLESS COMBUSTION TUBE
MOUNTING BRACKET
1/2" GAS COCK
AIR ORIFICE W/SCREEN (CONSULT FACTORY)
GLO-BAR IGNITOR
BURNER BOX CENTER PANEL
FAN BLOWER
33" INTERLOCKING HEAT DIFFUSER (BAFFLE)
2" X 4" OUTLET BOX
2" X 4" OUTLET BOX COVER
STRAIN RELIEF BUSHING
CONTROL BOX COVER GASKET (PER FOOT**)
RUBBER GROMMET
REFLECTOR CENTER SUPPORT
STAINLESS STEEL FLEX CONNECTOR
1/4" x 1/4" BRASS INT./EXT. ATMOS. BARB FITTING
REFLECTOR END CAP
REFLECTOR CLIP
5' AL-TI TUBE, PAINTED W. ONE CLAMP
ITEM
** 6’ TOTAL NEEDED TO COVER OUTER EDGES OF A BURNER BOX.
TP#
TP-1
TP-5
TP-9
TP-10
TP-11
TP-12
TP-14
TP-15
TP-16
TP-19B
TP-20C
TP-21B
TP-26A
TP-26B
TP-26D
TP-26E
TP-31B
TP-33B
TP-44
TP-50
TP-54
TP-55A
TP-65I
TP-66
TP-67
TP-68A
TP-70
TP-76
TP-82
TP-83
TP-97
TP-105
TP-106
TP-108
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
Basic Parts List
HL2 Series V.6/03 - 4” Tube Heater Installation, Operation, Maintenance and Parts Manual
Kit Contents & Product Features
Kit contents for the HL2 Series are shown below. Reference the proper column for your particular models length.
HL2 SERIES KIT CONTENTS
FILLED BY:
TP#
TP-19B
TP-21B
TP-33B
TP-82
TP-83
TP-105
TP-106
IOM
4" Hanger
TP-19B
DESCRIPTION
20 FOOT
4" Hangers
4" Tube Clamps
1/2" Gas Cock
4" Refl. Cntr. Sprt.
24" SS Flex Line
Refl. Endcaps
Refl. Endcap Clips
Install / Op Manual
4” Butt Clamp
TP-21B
Gas Cock
1/2" TP-33B
30 FOOT
3
2
1
2
1
2
8
1
4
3
1
3
1
2
8
1
Bag of Reflector
End Cap Clips.
TP-106
40 FOOT
50 FOOT
60 FOOT
70 FOOT
5
4
1
4
1
2
8
1
6
5*
1
5
1
2
8
1
7
6*
1
6
1
2
8
1
8
7*
1
7
1
2
8
1
24" SS Flex
Connect TP-83
Notes
4” Reflector Center
Support - TP-82
*One 4” stainless steel butt clamp is provided for each 175,000200,000 BTU model. Place as shown in IOM.
Product Features
APPROVALS
• IAS, CSA, CGA, CE.
• Indoor approval.
• Outdoor approval with OD-Kit.
• Commercial approval.
BURNER SIGHT GLASS
• For burner inspection.
COMBUSTION AIR INLET & VENT
• 4” Male duct.
ENAMELED CONTROL BOX
• Outside air collar (4”) attached.
• Totally enclosed components.
Reflector End
Caps TP-105
CONTROLS
• 100% safety shut off.
• Differential pressure switch.
• Silicon carbide hot surface igniter.
• Flame rod sensing.
• Pre and post purge controls.
• Microprocessor circuit board provides
soft lockout and self-diagnostic features.
EMITTER & COMBUSTION TUBES
• 16ga. 4” O.D. aluminized steel.
• All tubes coated with high temperature,
corrosion resistant black coating .95
emissivity. Slip fit connection.
• Titanium treated combustion chamber
(150-200 MBTU/H models).
12
General IOM
(LIOGT)
AND
HL2 Series Insert
(LIOHL2)
GAS CONNECTION
• 1/2” gas cock included.
• 7/8” flare-2’ S.S. flex included.
RADIANT SURFACE AREA (SQ. FT.)
• 20’ Models – 20.2 • 50’ Models – 50.6
• 30’ Models – 30.4 • 60’ Models – 60.7
• 40’ Models – 40.5 • 70’ Models – 70.9
WARRANTY
1 year - Burner box components.
5 years - Combustion and radiant tubes.
10 years - Stainless steel burner.
OTHER
• One reflector center support per reflector.
• Turbulator baffle included.
• Stainless steel upgrades available.
• Made in U.S.A.

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