Approvals Standards and Certifications. Brant Radiant Heaters HLV-170, HLV-80, HLV-50, HLV-90, HLV-140, HLV-60, HLV-100, HLV-175, HLV-75, HLV-180

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Approvals Standards and Certifications. Brant Radiant Heaters HLV-170, HLV-80, HLV-50, HLV-90, HLV-140, HLV-60, HLV-100, HLV-175, HLV-75, HLV-180 | Manualzz

HLV Series

1.0

Introduction •

Approval Standards and Certifications

Applications

Approval Standards and Certifications

Installation of this tube heater must comply with all applicable local, state and national specifications, regulations and building codes. Contact the local building inspector and/or fire Marshall for guidance.

In the absence of local codes, the installation must conform to the latest edition of:

United States: National Fuel Gas Code, ANSI Z223.1 (NFPA 54).

Canada: CAN/CGA B149.1, Canadian Electrical Code C22.1.

• ANSI Z83.20b - American National Standards Institute.

• OSHA - Occupational Safety & Health Administration.

• CSA - Canadian Standards Association.

• Indoor approval.

Applications

!

WARNING

Not For Residential Use. Installation of a commercial tube heater system in residential indoor spaces may result in property damage, serious injury or death.

This is

not an explosion proof heater. No tube heater may be used in a Class 1 or Class 2 Explosive

Environment. Consult your local Fire Marshall, insurance carrier and other authorities for approval if the proposed installation is in question.

Commercial/Industrial: Unless otherwise indicated, tube heaters are designed and certified for use in industrial and commercial buildings, such as warehouses, manufacturing plants, aircraft hangars and vehicle maintenance shops. For maximum safety the building must be evaluated for potential problems before installing the heating system. A critical safety factor to consider before installation is the clearance to combustibles (see pgs. 8-9).

Public Garages: Installation of this tube heater in public garages must conform with the Standard for

Parking Structures NFPA 88A (latest edition) or the Code for Motor Fuel Dispensing Facilities and Repair

Garages NFPA 30A (latest edition).

• Heaters must not be installed less than 8 ft. (2.4 m) above the floor. Minimum clearances to

combustibles must be maintained from vehicles parked below the heater.

• When installed over hoists, minimum clearances to combustibles must be maintained

from the upper most point of objects on the hoist.

Aircraft Hangars: Installation of this tube heater in aircraft hangars must conform with the Standard for

Aircraft Hangars, ANSI/NFPA 409 (latest edition).

• In areas adjoining the aircraft storage area (e.g., shops, offices) the bottom of heaters shall be

installed no less than 8 ft. (2.4 m) above the floor.

• Suspended or elevated heaters shall be located in spaces where they shall not be subject to damage

by aircraft, cranes, movable scaffolding or other objects.

High Altitude: Installation of this tube heater is approved, without modifications, for elevations up to

6,000 feet (1,829 m) MSL (sea level) in the United States. Contact the factory for installations above these elevations.

5

HLV Series

120V

- 120V HEATER INPUT -

F/N: LLV3EP1

HOT

NEUTRAL

EARTH

1/2” Gas Connection

Refer to Installation Manual

9”-14”

23cm-36cm

Gas Supply

Back Panel

120V

- 120V HEATER INPUT -

HOT

NEUTRAL

EARTH

1.0

Introduction •

Safety Labels and Locations

Air Metering Orifice

DO NOT REMOVE

TP-114

TP-3014

1 - 1/2"

F/N: LLAC

Air Metering Orifice

Gas Supply

Gas Supply

9” (23cm)

9” (23cm)

Gas Supply

1/2” Gas Connection

Refer to Installation Manual

9”-14”

23cm-36cm

Gas Supply

Gas Supply

Gas Supply

9” (23cm)

9” (23cm) Gas Supply

RE-VERBER-RAY LOW INTENSITY INFRARED HEATER

RADIATEUR A INFRAROUGE A FAIBLE INTENSITE

FOR INDOOR INSTALLATION ONLY. NOT FOR USE IN RESIDENTIAL DWELLING.

INSTALLATION À L’EXTÉRIEUR SEULEMENT. NE PAS INSTALLER DANS UN LOGEMENT.

MODEL /MODELE NO.

HLV-40-125N

VOLTS A.C.

120~60Hz

STARTING AMPS.

4.8

RUNNING AMPS.

1.1

COMBUSTION CHAMBER:

4” BC TITANIUM

INPUT BTU/H

125,000/95,000

MANIFOLD PRESSURE

3.5” WC

MIN. INLET PRESSURE

5.0” WC

ORIFICE SIZE

SA

MP

STAINLESS STEEL.

ANSI Z83.20b - 2011 CSA 2.32b - 2011 Low - Intensity Infrared Htr.

ANS Z83.20b - 2011 CSA - 2011 Low - Intensity Infrared Htr.

LE

FOR USE WITH

NATURAL GAS

HEATER TYPE

C1

VERSION

10/11

MIN. MOUNTING ANGLE:

0 DEGREES

MAX. MOUNTING ANGLE:

45 DEGREES

FOR INDOOR USE

BRANT RADIANT HEATERS LIMITED

34 SCOTT AVE., PARIS, ONTARIO

TEL: 1-519-442-7823 WWW.BRANTRADIANT.COM

SERIAL NO.

0870 XXXX XXXX 0001

Rating Plate

Gas Connection Label

F/N: LLV3EP2

Orange Crescent

Left Panel

(Controls Compartment)

SERVICE ACCESS PANEL

IGNITER & FLAME SENSE COMPARTMENT

2. Remove cover by lifting top

cover upward and outward.

CAUTION: HOT SURFACE.

KEEP COVER IN PLACE. REMOVE FOR SERVICE ONLY.

16” Burner Tube

F/N: LLV2EP9

Combustion

Chamber

F/N: LLV2EP15

Radiant

Tube

Right Panel

(Valve Compartment)

F/N: LLTB026

Yellow Titanium Alloy Tag

(150,000 BTU/H models and greater)

7

HLV Series

3.0

Installation

Reflector Assembly

Common Reflector Accessories

Figure 3.15

• Common Reflector Accessories

Elbow Reflector* (P/N: RE)

Highly polished aluminum reflector used over a 90° elbow accessory fitting.

U-shaped Reflector* (P/N: RU)

Highly polished aluminum reflector used over a 180°

U-bend accessory fitting.

Tee Reflector (P/N: V-RTE)

Highly polished aluminum reflector used to cover a

V-T or V-TI tee fitting.

Cross Reflector* (P/N: V-RCR)

Highly polished aluminum reflector used to cover a

V-CR cross fitting.

Side shield extension** (P/N: SSE)

Highly polished side shield extension used to direct infrared rays downward, away from sidewalls and combustibles.

* Reflectors cannot be rotated once reflector accessories are installed.

** Refer to the Clearance to Combustibles data found in Chart 1.2, P.9 for minimum distances to

combustibles when side shield extension(s) are used.

Complete vacuum system options are detailed in the Detroit Radiant Products Company HLV Series

Accessory Guide (F/N: LPKHLV) or online at www.detroitradiant.com.

29

3.0

Installation •

Burner Assembly and Mounting

HLV Series

Burner Assembly and Mounting

!

WARNING

Conditions such as wind drafts or other variables can cause movement of the heater and may require it to be rigidly mounted. Avoid excessive movement and/or vibration of the gas connection by rigidly mounting the burner control box. All remaining hanging points should use chains to allow for expansion.

The heater must be independently supported and in no case shall the gas or electrical supply support the weight of the heater.

1

Determine the mounting chain locations for hanging the burner control box.

2

Fasten beam clamp, screw hook or other type of suspension anchor to hanging point.

3

Attach S-Hook and #1 double loop chain (P/N: THCS) to anchor. Check that it is securely connected.

4

Attach chain assemblies and S-Hooks to mounting brackets on the burner control box. Adjust chain lengths until level and in straight alignment with radiant tubes (Figure 3.16).

Figure 3.16 • Burner Control Box Assembly • Side View

Burner box mounting bracket

Burner tube is in straight alignment with 10 ft. Primary

Combustion Chamber

8.1”

12”

Burner Sight Glass

(bottom side of the tube)

16”

Figure 3.17 • Burner Control Box • End View

18”

3.5”

5.5”

5”

3”

8.1”

30 31

HLV Series

Flue Venting

3.0

Installation

Venting Requirements

!

WARNING

Insufficient ventilation and/or improperly sealed vents may release gas into the building which could result in health problems, carbon monoxide poisoning or death.

Improper venting may result in fire, explosion, injury or death.

Seal vent pipes with high temperature sealant and three (3) #8 sheet metal screws.

Vent enclosed spaces and buildings according to the guidelines in this manual and applicable national, state, provincial and local codes.

Prior to installing vent material, the following guidelines and all applicable codes must be observed to ensure proper system performance and safety. Local codes may vary. In the absence of local codes, refer to and comply with the National Fuel Gas Code ANSI Z223.1 (NFPA 54) latest edition. In Canada, refer to and comply with CAN/CGA B149.1 and B149.2 Installation Codes for Gas Burning Appliances, or the National Standards of Canada.

Flue Venting General Requirements:

1

The HLV System is designed to operate with a 4 in. diameter exhaust vent.

2

Single-wall 26 gauge (min.) flue vent must be used. Use only corrosion resistant materials for the discharge line from the pump to the point of discharge.

3

The use of an approved wall or roof thimble and double-wall Type B-vent is required for the portion of vent pipe that runs through combustible material in the building wall or roof.

4

Seal all flue vents with high temperature sealant and three (3) #8 sheet metal screws to prevent leakage of flue gases.

5

Maximum vent length is 25 ft.; minimum of 2 ft. If needs are otherwise, consult factory for approval.

6

Do not use more than two 90° elbows in the exhaust vent.

7

Protect vent cap from potential blockages, such as snow.

8

Vent must terminate a minimum of 4 ft. (1.2 m) below, 4 ft. (1.2 m) horizontally from, and 1 ft.

(30 cm) above any window or door that may be opened or gravity air inlet into the building.

9

Vent must terminate a minimum of 3 ft. (.9 m) above any forced air inlet that is located within

10 ft. (3.1 m).

The bottom of the vent terminal must be located a minimum of 12 in. (30 cm) above grade level and must extend beyond any combustible overhang. Vents adjacent to public walkways must terminate a minimum of 7 ft. (2.1 m) above grade level.

Vent must be a minimum of 36 in. below or extend beyond any combustible overhang.

Protect the building from potential damage or discoloration resulting from flue gases by maintaining a minimum distance of 6 inches from the sidewall of the building. On

condensing

systems, extend the vent a minimum of 2 ft. beyond the building exterior to protect from condensate drippage.

13

A condensate trap is required on

condensing systems if a vertical rise exists in the discharge line (Figure 3.19). For ease of condensate disposal, horizontal venting is recommended. Unless local codes dictate otherwise, the condensate trap can be eliminated if a horizontal discharge is pitched downward 1 in./Ft. (Figure 3.18). Adhere to local codes for proper condensate disposal.

Consult the NFPA ANSI Z223.1 Gas Vent Termination criteria if roof pitch exceeds 9:12.

15

The vent terminal must extend a minimum of 2 ft. (.6 m) above the roof.

31

3.0

Installation •

Venting Requirements

HLV Series

Figure 3.18 •

Horizontal Flue Venting (Preferred)

A storm collar is recommended to prevent drippage back flow

Horizontal venting must slope downward 1 inch per foot

*It is recommended to extend at least 24 in. past building to avoid potential building discoloration.

24”*

Adhere to local codes for condensate disposal

Figure 3.19 • Vertical Flue Venting

Isolation Boot

Condensate trap assembly.

(Not required on horizontal venting unless specified or local codes require such).

Vacuum Pump

24” Min.**

Isolation Boot

Adhere to local codes for condensate disposal.

** Consult the NFPA ANSI Z223.1 Gas Vent

Termination Criteria if roof pitch exceeds 9:12

32

Condensate trap assembly

Where required.

(P/N: V-CT)

33

HLV Series

3.0

Installation

Combustion Air Requirements

Combustion Air Requirements

This heater has a factory preset air orifice to provide adequate combustion air intake to the unit.

Non-contaminated outside air for combustion

must be ducted to the heater if any of the following apply:

• Chemicals such as chlorinated or fluorinated hydrocarbons are present in the space where the heater

is installed (typical sources are refrigerants, solvents, adhesives, degreasers, paints, paint removers,

lubricants, pesticides, etc.).

• Negative building pressure.

Indoor air supply: If using combustion air intake from indoors, the required volume of the space must be a minimum of 50 ft

3

per 1000 Btu/hr (4.8 m

3

/kW) unless the building is of unusually tight construction. If the building is of unusually tight construction with air infiltration rates of less than 0.40 air changes per hour, outside combustion air is typically needed unless the sheer size of the building allows otherwise.

Contact the factory for further determination of air infiltration rates.

Outside air supply: Outside combustion air may be supplied via an accessory air duct attached directly over the air orifice. A wall inlet cap (P/N: WIV) must be used with horizontal air intake ducts. It is recommended that the air intake pipe is connected to the heater with a 4 in. diameter flexible air inlet boot

(P/N: AIRH) to allow flexibility for expansion (Figure 3.20). Sidewall (horizontal) air intake is preferred.

Refer to Chart 3.3 for limitations on the length and size of air intake ducts.

• A maximum of two elbows is allowed in the vent.

• Keep air intake opening a minimum of 4 ft. from any exhaust vent openings. Always place vent stacks

higher than air intake openings.

• An air intake cap (P/N: WIV) must be installed to prevent blockages. Locate intake cap in an area

where dirt, steam, snow, etc. Will not contaminate or clog the intake screen.

• Insulated duct or PVC pipe should be used in humid applications to prevent condensation on the outer

surface of the intake pipe.

Figure 3.20 • Outside Combustion Air Supply

Air Intake Cap

Burner Control Box

Air Inlet Boot

Chart 3.3 • Combustion Air Intake Limitations

Duct Size

4 in. O.D.

5 in. O.D.

Maximum Length

30 ft.

45 ft.

6 in. O.D.

75 ft.

NOTE: A powered air inlet (P/N: V-PAI) can be used to bring in outside air for combustion for runs exceeding 20 ft. up to a 150 ft. maximum run.

33

3.0

Installation •

Electrical Requirements

Electrical Data

HLV Series

Electrical Requirements

!

WARNING

Electric Shock

Field wiring to the tube heater must be connected and grounded in accordance with national, state, provincial, local codes and to the guidelines in the Tube Heater General Manual and

Series Insert Manual. In the United States refer to the most current revisions to the ANSI/NFPA

70 Standard and in Canada refer to the most current revisions to the CSA C22.1 Part I Standard.

• An HLV Series vacuum system operates on 120V, 60 Hz. If an alternate voltage will be used, consult

the factory.

• The HLV Series vacuum system is designed to operate as a two-stage system unless it has been

factory configured to operate as a single-stage system (P/N: V-1SAO). Reference the appropriate field

and internal wiring diagrams (Figures 3.21-3.25) for the system being installed.

• Amperage draws for individual system components are indicated in Chart 3.4.

• The circuit(s) must be sufficient to handle the starting amperage of all burner control boxes and the

running amperage of the vacuum pump.

• Wiring from the power supply to the pump and control panel assembly must be 12 AWG or larger to

maintain proper voltage under full load conditions.

• The circuitry for the pre-wired pump and control panel assembly is suitable for up to a 20 amp circuit

maximum.

• Confirm the control panel assembly remains as wired from factory for proper fan rotation. Check

directional arrow on pump housing for proper wheel rotation (excludes NC-7 Series pump).

NOTE: Each vacuum pump is equipped with one control panel which is factory wired for up to two temperature zones (Figure 3.25, p.38).

Chart 3.4 • HLV Burner and Vacuum Pump Electrical Data

HLV Burner Box

Starting Circuit

0.7 amp

(per burner)

HLV Burner Box

Running Circuit

0.2 amp

(per burner)

HLV Pump

Model No.

NC-7

Running

Circuit

1.95 amps

PB-8

PB-9

PB-10A

7.4 amps

9.6 amps

11.6 amps

Voltage

115 VAC;

60Hz-1Ph

115/230 VAC;

60Hz-1Ph

115/208-230 VAC;

60Hz-1Ph

115/230 VAC;

60Hz-1Ph

RPM’s

3000

3450

3450

3450

HP

1/15

1/2

3/4

1

34 35

HLV Series

3.0

Installation

Electrical Requirements

Field Wiring

Wiring

Figure 3.21

• Two-Stage System Field Wiring Diagram

VACUUM PUMP

CONTROL BOX

(MOUNTED TO PUMP)

24V INPUT

FOR ZONE

#1

24V INPUT

FOR ZONE

#2

(IF USED)

N

L1

G

This shows additional wiring for systems that will operate on two temperature zones. NOTE: Do not exceed the total number of burners allowed per system as stated in Chart 2.3 on page 18.

N 1 2 N 1 2

24V Two Stage Controller

24V OUT - Stage 2

(High Fire)

24V OUT - Stage 1

(Low Fire)

24V IN

Common

External Transformer

(Field Supplied)

24V Two Stage Controller

24V OUT - Stage 2

(High Fire)

24V OUT - Stage 1

(Low Fire)

24V IN

Common

External Transformer

(Field Supplied)

A common wire is required for thermostats that require constant power.

A common wire is required for thermostats that require constant power.

Figure 3.22

• Single-Stage System Field Wiring Diagram (V-1SAO)

VACUUM PUMP

CONTROL BOX

(MOUNTED TO PUMP)

24V INPUT

FOR ZONE

#1

24V INPUT

FOR ZONE

#2

(IF USED)

N

L1

G

This shows additional wiring for systems that will operate on two temperature zones.

NOTE: Do not exceed the total number of burners allowed per system as stated in Chart 2.3 on page 18.

COM 24VAC COM 24VAC

COM 24VAC COM 24VAC

24V Digital

Thermostat

W

R

Common

External Transformer

(Field Supplied)

A common wire is required for thermostats that require constant power.

24V Two Stage Controller

W

R

Common

External Transformer

(Field Supplied)

A common wire is required for thermostats that require constant power.

35

3.0

Installation

Electrical Requirements

Internal Wiring

HLV Series

Before field wiring this appliance - Check existing wiring; replace if necessary.

NOTE: If any of the original wire supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C.

Figure 3.23 • Internal Burner Control Box Block Wiring Diagram

G

G

SINGLE STAGE ONLY (V-1SAO)

*WIRE REMOVED

36 37

HLV Series

3.0

Installation

Electrical Requirements

Internal Wiring

Before field wiring this appliance - Check existing wiring; replace if necessary.

NOTE: If any of the original wire supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C.

Figure 3.24 • Internal Burner Control Box Ladder Wiring Diagram

BK

G

120VAC

24VAC

BK

G

SINGLE STAGE ONLY (V-1SAO)

*WIRE REMOVED

37

3.0

Installation

Electrical Requirements

Pump & Panel Wiring

HLV Series

Figure 3.25 • Pump and Panel Assembly Internal Wiring

NOTE: In North America, the pump and panel are pre-wired at the factory for 120V. If an alternate voltage is to be used consult the factory.

Wiring from the power supply to the panel and pump must be 12 AWG or larger to maintain proper voltage under full load conditions.

The circuitry for the panel and pump is suitable for a 20 AMP circuit maximum.

G

W

R

Y

BL

4

3

2

1

Y

BL

BL

BL

8

6

4 2

R

1

24V COIL

0

NC

NO

COM

24V COIL

O

GY

BL

BL

NC

NO

COM

24V COIL

O

24V INPUT

FOR ZONE #1

GY

24V INPUT

FOR ZONE #2

(IF USED)

38

W W

N

W

BK

R

R

L1

OPTIONAL

230VAC INPUT

120VAC

(FACTORY ORDERED)

G

39

HLV Series

Gas Supply

3.0

Installation

Gas Supply

!

WARNING

Improperly connected gas lines may result in fire, explosion, poisonous fumes, toxic gases, asphyxiation or death. Connect gas lines in accordance to national, state, provincial and local codes.

The installation must conform with local building codes or, in the absence of such codes, the National Fuel

Code (NFPA 54) and in conjunction with ANSI Z21.24/CSA 6.10 “Connectors for Gas Appliances”.

Important! Before connecting the gas supply to the burner control box:

• Verify that the heater’s gas type (as listed on the rating plate) matches that of your application.

NOTE: Unless otherwise noted on the rating plate, this infrared heater is designed and orificed to

operate on standard BTU gas. Contact the factory if utilizing non-standard BTU gas.

• Check that the gas piping and service has the capacity to handle the total gas consumption of all

heaters being installed, as well as any other gas appliances being connected to the supply line.

• Check that the main gas supply line is of proper diameter to supply the required fuel pressures.

• If utilizing used pipe, verify that its condition is clean and comparable to a new pipe. Test all gas

supply lines in accordance with local codes.

• Test and confirm that inlet pressures are correct. Refer to the heater rating plate for gas type and

the required minimum and maximum pressures (Chart 3.5). The gas supply pipe must be of

sufficient size to provide the required capacity and inlet pressure to the heater (if necessary,

consult the local gas company). Do not exceed the maximum allowed pressures for the heater,

the space or the gas piping system.

Chart 3.5 Manifold Pressure

Type of Gas

Natural

Propane

Required Manifold

Pressure

3.5 Inches W.C.

10.0 Inches W.C.

Minimum Inlet

Pressure

5.0 Inches W.C.

11.0 Inches W.C.

Maximum Inlet

Pressure

14.0 Inches W.C.

14.0 Inches W.C.

NOTE: Check manifold pressure at the tap on the gas valve. Small variations in manifold pressure

(actual vs. published) may exist due to changing atmospheric conditions. Readings will be above atmospheric pressure.

39

3.0

Installation • Gas Supply

HLV Series

!

WARNING

An approved connector, suitable for the environment of equipment usage, is required.

Visible or excessive swaying, flexing and vibration of the gas connections must be avoided to prevent failure. In no case shall the gas or electrical supply support the weight of the heater.

IMPORTANT! The heating system will expand and contract during operation. Allowances for

expansion must be made between the connection to the heater and the gas supply. Excessive bending, kinks, twists or vibration must be avoided. A flexible gas connection of approved type is required. A type 1 rubber gas connectors installed in one plane, and without sharp bends, kinks or twists.

The gas pipe and connection

must be supported independently. Do not install gas supply line in a manner that bears the weight of the heater. Connect the main gas supply line with an approved flexible connector

(Figures 3.26-3.27) or, if national or local codes require rigid piping, a swing joint. Heater shall not be connected to the building piping system with rigid pipe or semi-rigid metallic tubing, including copper.

When using such material, an intermediate connection device that allows for heater expansion must be used.

The gas outlet must be in the same room as the appliance and accessible. It may not be concealed within or run through any wall, floor or partition. When installing the heater in a corrosive environment (or near corrosive substances), use a gas connector suitable for the environment. Do not use the gas piping system to electrically ground the heater.

1

Install a sediment trap / drip leg if condensation may occur at any point of the gas supply line or as required. This decreases the possibility of loose scale or dirt in the supply line entering the heater’s control system and causing a malfunction.

NOTE: High pressure gas above 14 Inches W.C.. (water column pressure) requires a high pressure regulator and ball valve.

2

Form the Type 1 rubber gas hose into a smooth U-shape allowing a maximum of 14 in. between the flexible connector’s end nuts (Figures 3.26-3.27).

3

Attach the ball valve to the gas supply pipe. Apply pipe compound to NPT adapter threads to seal the joint. Use only a pipe compound resistant to LP.

NOTE: Provide a 1/8 in. NPT plugged tapping accessible for test gauge connection immediately upstream of gas connection to the heater (provided on ball valve).

4

Attach the flexible connector to the adapter and burner control box inlet. Seal the joints.

Note: Excessive torque on the manifold may misalign the orifice. Always use two wrenches to tighten mating pipe connections.

5

Final assembly must be tested for gas leaks according to NFPA 54 and all local codes and/or Standards.

!

WARNING

Testing for gas leaks with an open flame or other sources of ignition may lead to a fire or explosion and cause serious injury or death. Test in accordance with relevant codes of practice.

40 41

HLV Series

Figure 3.26

• Flexible Gas Connection • Side View

Ball Valve / Inlet Tap

Adapter

Elbow

Elbow

Adapter

Drip Leg/

Sediment Trap

3.0

Installation

Gas Supply

Heater Movement*

Burner

Control Box

Side View

7”-14”

Type 1 Hose Gas Connector, formed into a U-bend

Figure 3.27

• Flexible Gas Connection • Rear View

Ball Valve / Inlet Tap

Burner Control Box

End View

Hose connections must be installed inline in the same direction as heater expansion

NOTE: Do not exceed 14 Inches W.C. to the appliance.

41

4.0

Operation

Lighting and Shutdown • Sequence of Operation

4.0

Operation

HLV Series

!

WARNING

This heater must be installed and serviced by trained gas installation and service personnel only.

Do not bypass any safety features or the heater’s built in safety mechanisms will be compromised.

Burner Lighting Instructions

1

Purge main gas supply line.

2

Rotate heater’s manual ball valve to the “ON” position.

3

Close electrical circuit (turn on thermostat).

4

If the burner fails to light, turn “OFF” gas and wait five minutes before repeating the above procedure.

Burner Shutdown Instructions

1

Open electrical circuit (turn off thermostat).

2

Rotate heater’s manual ball valve to the “OFF” position.

Sequence of Operation

Starting Circuit: Upon a call for heat, power is supplied to the relays at the burner box(es) and vacuum pump. The vacuum pump is energized creating negative air pressure. This allows the differential pressure switch in the burner box(es) to close which completes a low voltage circuit from the secondary side of the transformer to the ignition module. After the ignitor has been powered for seven seconds, the gas valve opens initiating the ignition trial. If flame is not sensed after 15 seconds, the heater will attempt to re-ignite for a total of three trials for ignition before entering lockout mode.

Single Stage Running Circuit: After ignition, the flame rod monitors burner flame. If sense of flame is lost, the control closes the gas valve within one second and a new trial sequence (identical to the starting sequence) is initiated.

The control can be reset by briefly interrupting the power source.

Two Stage Running Circuit (when applicable

): The second stage on the gas valve is powered directly from the second stage of the thermostat. In order for two stage to flow to a higher output, single stage must be energized as well. The thermostat determines which stage to maintain for the desired temperature.

42 43

HLV Series

3.0

Operation • Thermostat • Diagnostics • Operation Indicator Lights

Thermostat

NOTE: Different thermostats operate according to their particular features. Refer to thermostat specifications for details.

HLV Series heaters require a 24V, two stage thermostat to operate. The burner control box is equipped with a round terminal strip that accepts three (3) 1/4” insulated female spade terminals. Do not supply

120V to the 24V connection.

Theoretical Example: The thermostat is set to 65° F. The thermostat’s preset differential for high fire mode is 3° F.

When the temperature drops below the setpoint of the thermostat (65° F), low fire will activate. If the temperature continues to drop below the setpoint by another 3° F (62° F), high fire will activate bringing the temperature back up to the thermostat’s setpoint.

Diagnostics

The controls will automatically lockout the heater system when an external or system fault occurs.

Lockout: If proof of flame is not established, a component failure occurs or blockages are evident, the heater will enter hard lockout. If lockout occurs, the control can be reset by briefly interrupting the power source. Refer to Chart 4.1 below for a description of the control module diagnostic indicator flash codes.

Chart 4.1 • Control Module Diagnostic Flash Codes

LED Flash Code

Steady ON

1 Flash

2 Flashes

Fault Status

Control Fault

Air Flow Fault

Flame - No call for heat

3 Flashes Ignition Lockout

NOTE: Flash code indicator light is located internally on the control module.

Figure 4.1

• Operational Indicator Lights

Light 1* (amber)

Indicates High

Fire Mode

Light 2 (amber)

Indicates Low

Fire Mode

Light 3 (amber)

Pressure Switch

Operational Indicator Lights

*

Models with V-1SAO add-on are not equipped with high fire light.

43

4.0

Operation

System Start-Up and Damper Adjustment

HLV Series

System Start-Up Prechecks

• Confirm all gas piping, electrical wiring, etc. are properly installed.

• Preset the primary and secondary damper(s) to half-open.

• If applicable, unassisted combustion air ducts must be installed before start-up.

• If applicable, fan assisted outside combustion air ducts must not be connected to burner control box

upon initial start-up.

Damper Adjustment

1

The system must run for 20 minutes in

high fire mode before setting the dampers. Confirm all operational indicator lights (located on the burner control box) are on.

2

All system dampers are preset to half-open. If a burner fails to stay lit or does not light, the damper serving that burner must be adjusted until the burner is continually lit throughout the initial 20 minute start-up.

3

Using a manometer with an adequate range, measure the vacuum pressure (Figure 4.2) at the burner furthest from the vacuum pump. Adjust the primary damper at the pump until the manometer reaches the specified reading shown in Chart 4.2.

NOTE: If proper box static pressure cannot be achieved, it may be necessary to remove one, two or all three baffle sections (P. 27). Consult factory following basic troubleshooting (i.e. proper pump rotation, check for blockages, baffle installed correctly, control box covers are secured, etc.).

Figure 4.2 • Burner Control Box Vacuum Port

NOTE: Remove the plug on vacuum port to measure box pressure. Ensure burner box lid is tightened securely.

Vacuum Port

4

If secondary dampers are installed in the system, connect manometer to each applicable burner and set applicable secondary damper to the specified reading (Chart 4.2).

5

Once each damper has been adjusted, burner pressures must be checked to confirm initial setpoints did not change. Readjust dampers as necessary in the same order. Lock dampers in place.

6

If fan assisted outside air ducts are used, connect to control box after initial start-up is complete;

Adjust supply dampers (supplied with powered air inlet P/N: V-PAI - sold separately) until the required pressures are achieved.

Chart 4.2 • Burner Box Pressure Setpoints

Burner Box Input (BTU/H) Box Pressure (inches W.C.)

40,000 to 60,000 -0.51 +/- .01

75,000 to 110,000 -0.19 +/- .01

120,000 to 180,000

200,000

-0.22 +/- .01

-0.19 +/- .01

The system must operate in high fire for 20 minutes before adjusting the dampers.

Each system damper must be adjusted to the box pressure setpoints listed above.

44 45

HLV Series

5.0

Maintenance •

Routine Inspection

5.0

Maintenance

!

WARNING

Personal injury or death may result if maintenance is not performed by properly trained gas installer or service personnel. Contact the installing distributor or place of purchase for service. Do not operate heating system if repairs are necessary.

Allow heater to cool prior to servicing.

Disconnect power to heater before servicing.

Use protective glasses when maintaining the heater.

Routine Inspection:

At least once per year, the heating system should be inspected and serviced by trained gas installation and service personnel only. This inspection should be performed at the beginning of the heating season to insure that all heater components are in proper working order and that the heating system operates at peak performance. Particular attention should be paid to the following items.

• Vent pipe system: Check the outside termination and the connections at the heater. Inspect the vent exhausts for leakage, damage, fatigue, corrosion and obstructions. If dirt becomes a problem, installation of outside air intake ducts for combustion is recommended.

• Combustion air intake system (when applicable): Check for blockage and/or leakage. Check the outside termination and the connection at the heater.

• Heat exchangers: Check the integrity of the heat exchangers and tailpipe. Replace if there are signs of structural failure. Check for corrosion and/or buildup within the tube exchanger passageways.

• Burner: Check for proper ignition, burner flame and flame sense. Flame should extend directly outward from burner without floating or lifting.

• Exhauster: Inspect the exhauster system for abnormal noise and/or vibrations. Consult factory for troubleshooting.

• Wiring: Check electrical connections for tightness and/or corrosion. Check wires for damage.

• Gas Connection: Inspect the integrity of the gas connection to the heater. Check for leaks, damage, fatigue or corrosion. Do not operate if repairs are necessary and turn off gas supply to the heater.

Contact service personnel.

Reflectors: To maintain effective infrared heating, always keep both sides of the reflector clean.

Maintenance can vary significantly depending on the environment. Dirt and dust can be vacuumed or wiped with a soap and water solution. Use metal polish if the reflectors are severely dirty.

Contact service personnel if repairs are necessary. Do not operate unit.

45

5.0

Maintenance • Troubleshooting Guide

HLV Series Troubleshooting Guide

Turn up thermostat

Find the source of the electrical problem

Does the exhauster fan turn on?

Yes

No

No

Is the power at the exhauster 120V/220V?

Yes

HLV Series

Find the source of the electrical problem between the thermostat transformer, thermostat and panel.

No

Is the thermostat supplying 24V to the exhauster control panel?

Yes

Does the ignitor warm up and glow red?

Yes

No

Is power at the burner control box 120V/220V?

No

Find the source of the electrical problem.

Yes

Is the thermostat supplying

24V to the terminal plug on the burner control box?

Yes

No

Find the source of the electrical problem between the thermostat transformer, thermostat and panel.

After the ignitor is fully energized, does the gas valve open?

Yes

No

Test for 24V at valve opening period (usually 5 seconds after power to the burner control box). Is there 24V at the valve?

Yes

No

Replace circuit board and/or wiring harness.

Check to confirm gas pressure is within minimum and maximum inputs as indicated on the heater’s rating plate. Is gas pressure OK?

No

Correct problem.

Yes

Replace gas valve.

Replace the pressure switch

after verifying:

• Baffle(s) are in the radiant tube

furthest from the burner.

• Heater, fan blowers ,squirrel cage,

intake and exhaust are clean and

free from dirt and obstructions.

• The 4” air intake pipe does not

exceed 20 ft. and/or 2 elbows.

• There is not a negative pressure

experienced at the area of air

intake (e.g.; high winds, attic

space, tightly sealed building).

Continued on page 48

46 47

HLV Series

5.0

Maintenance • Troubleshooting Guide

*

NOTICE

Bypassing any switch is intended for testing purposes only. Do not leave switch bypassed during normal operation or the heater’s built-in safety mechanisms will be compromised.

The exhauster is faulty and must be replaced.

A faulty relay may exist in the panel assembly. Consult factory.

Yes Yes

Is the panel supplying

120V/220v to the exhauster?

No

Is there 24V on the secondary side of the transformer located in the panel assembly?

No

Replace transformer.

Is the ignitor physically damaged?

Yes

Replace ignitor.

Repair wiring or hose connections.

No

Check voltage during ignition sequence (usually 5 seconds after power to burner control box). Is it 24V?

No

Remove obstruction.

Yes

Is the resistance through the ignitor 1 to 6

?

Is the inlet or the outlet of the unit obstructed?

Yes

No

No

Yes

Replace faulty wiring.

No

Is there 24V between

L1 and ground at the circuit board?

Yes

No

Yes

Replace circuit board.

Check for loose wiring or restrictions in hose connections to the pressure switch. Are they OK?

No

Is there 24V on the secondary side of the transformer in the burner control box?

No

Yes

Replace ignitor.

Replace faulty wiring.

*

Temporarily place a jumper across the terminal of the safety pressure switch.

Set control box cover in place.

Does the ignitor glow red?

Yes

No

Adjust dampers until proper box pressures are achieved.

Replace faulty transformer. Note: The original transformer is equipped with an automatic resetting fuse. Confirm fuse has not been tripped.

Yes

After the system has run for 20 minutes in high fire mode, measure box pressures using a manometer with an adequate range.

Do the setpoints correspond with Chart 4.2 on page 44?

47

5.0

Maintenance • Troubleshooting Guide

Continued from page 46

Does the burner light?

Yes

No

Is the ball valve in the ON position?

No

Correct problem.

HLV Series

Yes

Check to confirm gas pressure is within minimum and maximum inputs as indicated on the heater’s rating plate. Is gas pressure OK?

Yes

No

Purge gas lines of air.

Correct problem.

Does the burner stay on?

Yes

No

Does the burner stay on for approximately 15 seconds and then shut off?

No

Does the burner come on and turn off immediately

(1 or 2 seconds)?

No

Remove restriction in the exhaust or replace the faulty pressure switch.

Yes

Yes

Is the heater properly grounded?

Is the polarity correct?

Yes

No

Correct problem.

No

Check to confirm gas pressure is within minimum and maximum inputs as indicated on the heater’s rating plate. Is gas pressure OK?

Yes

Does the heater stay ON until a call for heat ends?

Yes

No

The heater can shut down due to:

• Improper grounding.

• High winds.

• Taking combustion air from the attic.

• Dirty environment.

• Improperly positioned baffles (if applicable).

• Fluctuating gas pressure.

• Reduction of negative pressure as the system heats up (reset dampers).

Troubleshooting ends.

48 49

HLV Series

5.0

Maintenance • Troubleshooting Guide

This model has a flame rod sensor located next to the hot surface ignitor.

With an amp meter, check the amperage at the flame rod.

Is it greater than 7 amps?

Yes

No

Confirm the flame sensor wire is

OK and then replace circuit board.

The sensing rod is faulty or the flame is weak. Confirm that the heater is operating at proper gas pressures as indicated on the heater’s rating label.

Replace sensing rod if necessary.

49

5.0

Maintenance

Parts

Heater Burner Assembly Components

HLV Series

Replacement Parts

Figure 5.1

• Burner Assembly

Components

1

832

70

1251

219

1526A

31B

68A

NOPS

207

97

17

218

304, 1204

14

15

16

21B

1502

329

825

301

217

1283

321

221

222

222A

1250

214

11

828

1297

1229

5

1280

13

200A/201B

31B

13

223

204

9 10

333

RH-1,3

33B

114

76

212

1540A/1541A

208A

303

12

84

Chart 5.1 • Parts List

Part No. Description

RH-1,3

TP-1

TP-5

TP-9

TP-10

TP-11

TP-12

TP-13

TP-14

TP-15

TP-16

TP-17

Type 1 Rubber Gas Hose 1/2”, 3/4”

Control Box Cover

Flange Gasket

Conduit Coupling

Conduit 4” x 1/2”

Mini Ignitor Box

Mini Ignitor Box Cover

8 x 1/2” Self-Drilling Screw

Sight Glass Gasket

Sight Glass

Sight Glass Washer

Sight Glass Kit

TP-19B 4” Wire Hanger with Tension Spring

TP-20C 120” Aluminum Reflector

TP-20D 120” Optional Stainless Steel Reflector

TP-21B 4” Standard Tube Clamp

TP-26A 10 ft. Black Coated Aluminized Radiant Tube

TP-26B 10 ft. Black Coated Alum-Ti Combustion Tube

TP-26C 10 ft. Uncoated Hot-Rolled Radiant Tube

TP-26H 10 ft. 304 UC Stainless Steel Condensing Pipe

TP-31B Control Box Mounting Bracket

TP-33B 1/2” Shut-Off Ball Valve / Inlet Tap

TP-65I 36” Interlocking Turbulator Baffle

TP-68A Strain Relief Bushing

** 6 feet total required to cover outer edges of the

burner control box.

Part No.

Description

TP-70

TP-76

Control Box Cover Gasket (per foot**)

Rubber Grommet

TP-82

TP-84

TP-97

TP-105

Reflector Center Support (RCS)

1/2” Female / Male Flare Fitting

1/4” x 1/4” Brass Int./Ext. Atmos. Barb Fitting

Aluminum Reflector End Cap

TP-106

TP-113

Reflector End Cap Clips (8 pcs.)

Reflector Tension Spring

TP-114 Plastic Air Orifice with Screen

TP-200A Low BTU Burner (Blue) - consult factory

TP-201B Mid BTU Burner (Tan) - consult factory

TP-204 Gas Orifice (consult factory)

TP-207 Pressure Switch Mounting Bracket

TP-208A Gas Valve Mounting Bracket

TP-212

TP-214

1/2” x 3” Pipe Nipple

Mini Ignitor Wiring Harness

TP-217

TP-218

TP-219

TP-220

TP-221

TP-222

Pressure Switch Barb

Differential Switch Vinyl Sensing Tube (exhaust)

Differential Vinyl Sensing Tube (burner)

Stainless Steel Tube Clamp (175 & 200 MBH burners)

Mini Ignitor Holder Gasket

Flame Rod

50

TP-222A Flame Rod Wire

TP-223 Gas Manifold

51

HLV Series

5.0

Maintenance

Parts

Tube and Reflector Components

Figure 5.2

• Tube & Reflector Components

82

105

20C/20D

Co nd ens ing

Ta ilpi pe

26H

65I

106

1516B/1516C/1516D

113

19B

Co mb ust ion

Ch am ber

(s)

26B

Ra dia nt E mit ter

Tu be

(s)

26A/26C

21B/220

V-D/V-D-SS

V-24

Part No. Description

TP-301

TP-303

TP-304

TP-321

TP-329

TP-333

TP-825

TP-826

TP-828

Burner Control Box Center Panel

End Panel, Right

Burner Control Box Outer Shell (50-175MBH)

Ignition Plate Gasket

1/4 in. Neutral Terminal Block

72 in. 120V -Prong Power Cord

24V Isolation HLRB Relay Board

40VA Transformer

Yellow Operational Indicator Light

TP-832 Thermostat Terminal Strip

TP-1204 Burner Control Box Outer Shell (200MBH)

TP-1216 NC-7 Exhauster Pump

TP-1229 Fuse Holder

TP-1250 24V Mini Ignitor

TP-1251 Triton 6465H Circuit Board

TP-1255 NC-7 Pump Assembly w/ Control Panel

TP-1280 16” Flanged Burner Tube with Fittings

TP-1283 Mini Ignitor Plate

TP-1289 NC-7 Exhauster Pump Mounting Tube

TP-1297 Fuse

TP-1502 End Panel, Left

TP-1516B 1/2 HP PB-8 Motor

TP-1516C 3/4 HP PB-9 Motor

TP-1516D 1 HP PB-10A Motor

21B

1216/1255

V55A/V56A/V57A

V-23

1289

1528

1565

V301/V302/V303

1525

826

1527

832

1566

Part No.

Description

TP-1525 Vacuum Exhauster Relay

TP-1526A 75VA Transformer with Foot Mounts

TP-1527

TP-1528

24V Switching Control Relay

Exhauster Post Purge Relay Timer

TP-1540A 36G54-224 Gas Valve - Natural Gas Assembly

TP-1541A 36G54-226 Gas Valve - LP Gas Assembly

TP-1565

TP-1566

8” x 8” Electrical Box

Exhauster Control Panel Assembly

TP-NOPS Normally Open Pressure Switch (see below)

TP-264B Differential Pressure Switch, 40 to 80 MBH

TP-264E Differential Pressure Switch, 90 to 125 MBH

TP-1264A Differential Pressure Switch, 140 to 180 MBH

TP-264F Differential Pressure Switch, 200 MBH

V-D

V-D-SS

V-23

V-24

V-55A

Damper (NC-7 pumps)

Damper (PB Series pumps)

Isolation Boot x2 (pump inlet and outlet)

Worm Gear Clamp

4” Adapter for PB-8 (x2) or PB-9 (x1)

V-56A

V-57A

V-301

V-302

V-303

5” Adapter for PB-9 (x1) or PB-10 (x1)

6” Adapter for PB-10 (x1)

PB-8 Pump Assembly

(panel & accessories not included)

PB-9 Pump Assembly

(panel & accessories not included)

PB-10A Pump Assembly

(panel & accessories not included)

51

6.0

Limited Warranty •

Kit Contents Check List

HLV Series

6.0

Limited Warranty

One-Year Limited Warranty. Radiant Tube Heaters covered in this manual, are warranted by Brant Radiant Heaters Limited to the original user against defects in workmanship or materials under normal use for one year after date of purchase. Any part which is determined to be defective in material or workmanship and returned to an authorized service location, as Brant Radiant

Heaters Limited designates, shipping costs prepaid, will be, as the exclusive remedy, repaired or replaced at Brant Radiant

Heaters Limited’s option. For limited warranty claim procedures, see PROMPT DISPOSITION below. This limited warranty gives purchasers specific legal rights which vary from jurisdiction to jurisdiction.

Additional Limited Warranty. In addition to the above mentioned one-year warranty, Brant Radiant Heaters Limited warrants the original purchaser an additional extension on the combustion chamber, radiant tubes and stainless steel burner. This extension excludes electrical/purchased components. See specific product warranties on page 52 of the Series Manual.

General Conditions. The Company will not be responsible for labor charges for the analysis of a detective condition of the heater or of the installation of replacement parts. The warranties provided herein will not apply if the input of the heater exceeds the rated input at time of manufacturing or if the heater in the judgement of the Company has been subjected to misuse, excessive dust, improper conversion, negligence, accident, corrosive atmospheres, excessive thermal shock, excessive vibration, physical damage to the heater, alterations by unauthorized service personnel , operation contrary to the Company’s instructions or if the serial number has been altered, defected, or removed. The Company shall not liable for any default or delay in the performance of these warranties caused by contingency beyond its control, including war, government restriction or restraints, strikes, fire, flood, short or reduced supply of raw materials, or parts.

The warranties herein shall be null and void if the heater is not installed by a competent heating contractor and/or if the heater is not installed according to Company instructions, normal industry practices and/or if the heater is not maintained and repaired according to Company instructions. Normal product degradation and wear (rust, oxidation, etc.) does not constitute a material defect and applicable warranty claim.

Limitation of Liability. To the extent allowable under applicable law, Brant Radiant Heaters Limited’s liability for consequential and incidental damages is expressly disclaimed. Brant Radiant Heaters Limited’s liability in all events is limited to and shall not exceed the purchase price paid.

Warranty Disclaimer. Brant Radiant Heaters Limited has made a diligent effort to provide product information and illustrate the products in this literature accurately; however, such information and illustrations are for the sole purpose of identification, and do not express or imply a warranty that the products are merchantable, or fit for a particular purpose, or that the products will necessarily conform to the illustrations or descriptions. Except as provided below, no warranty or affirmation of fact, expressed or implied, other than as stated in the “LIMITED WARRANTY” above is made or authorized by Brant Radiant Heaters Limited.

Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products for certain purposes, which may vary from those in neighboring areas. While Brant Radiant Heaters Limited attempts to assure that its products comply with as many codes, it cannot guarantee compliance, and cannot be responsible for how the product is installed or used. Before purchase and use of the product, installation, and use will comply with them. Certain aspects of disclaimers are not applicable to consumer products: e.g.,(a) some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you: (b) also, some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to you: and (c) by law, during the period of this limited warranty, any implied warranties of implied merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.

Prompt Disposition. Brant Radiant Heaters Limited will make a good faith effort for prompt correction or other adjustment with respect to any product which proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to resolve satisfactorily, write to Brant Radiant Heaters Limited at address below, giving dealer’s name, address, date and number of the dealer’s invoice, and describe the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was damaged in transit to you file claim with carrier.

© 2011 Brant Radiant Heaters Limited

34 Scott Avenue • Paris, Ontario, Canada N3L 3R1

Phone (519) 442-7823 Fax (519) 442-7321 www.brantradiant.com • [email protected]

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