Detroit Radiant Products HLV Series Design, Installation, Operation, And Maintenance Manual
Tube heater vacuum system
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HLV Series Tube Heater
Vacuum System
Design, Installation, Operation, and Maintenance Manual
The HLV Series Infrared Tube Heater is a negative pressure, two stage radiant heater vacuum system
designed to provide comfort heat. Consisting of four main components (a burner control box, radiant
tubes, reflector assembly, and vacuum exhauster), this system generates infrared energy to heat the
objects in the space. These objects then reradiate this heat, creating a comfort zone at the floor level.
This allows large spaces to be heated efficiently without having to provide primary infrared for every
square foot of space.
Improper installation, adjustment, alteration, service, or maintenance can cause
property damage, injury, or death. Read the installation, operation, and
maintenance instructions thoroughly before installing or servicing this equipment.
This heater must be installed and serviced by trained gas installation and service
personnel only. Failure to comply could result in personal injury, asphyxiation,
death, fire, or property damage.
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, in the absence of such thermostats, in a
conspicuous location.
Not for residential use! Do not use this heater in the home, sleeping quarters,
attached garages, etc. Installation of a commercial tube heater system in
residential indoor spaces may result in property damage, serious injury,
asphyxiation, or death.
For Your Safety
If you smell gas:
• Do not try to light any appliance.
• Do not touch any electrical switch.
• Do not use any phone in your building. • If you cannot reach your gas supplier, call the fire department.
INSTALLER: Present this manual to the end user.
Keep these instructions in a clean and dry place for future reference.
Model#: ______________________ Serial #: _____________________________
WARNING
!
• Immediately call your gas supplier from a neighbor's phone.
• Follow the gas supplier's instructions.
(located on rating label)
LIOHLV-Rev. 21711
Print: 2M-02/17_r5-03/21 (CDS)
Replaces: LIOHLV-2M-3/15(CDS)
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Table of Contents
Related Manuals for Detroit Radiant Products HLV Series
Summary of Contents for Detroit Radiant Products HLV Series
- Page 1 Vacuum System Design, Installation, Operation, and Maintenance Manual The HLV Series Infrared Tube Heater is a negative pressure, two stage radiant heater vacuum system designed to provide comfort heat. Consisting of four main components (a burner control box, radiant tubes, reflector assembly, and vacuum exhauster), this system generates infrared energy to heat the objects in the space.
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Page 2: Table Of Contents
Series Table of Contents Contents 1.0 Introduction ..................3 Specifications . -
Page 3: Introduction
Materials not included in the heater kit contents (i.e. screws, vent material, terminals, etc.) are the responsibility of the installer. Notify your product representative or Detroit Radiant Products of any discrepancy or missing kit contents prior to installing unit. Figure 1.1 •... -
Page 4: Specifications
Introduction • Specifications Series Specifications Chart 1.1 • HLV Series Specifications Approximate Component Hanging Weights Per 10 Ft. Per 10 Ft. Radiant Combustion Typical Radiant Pipe Tailpipe & Emitter Condensing Burner Mounting Chamber BTU/h BTU/h Burner & Reflector Reflector Tube(s)**... -
Page 5: Standards, Certifications, And Government Regulations
Introduction • Standards, Certifications, and Government Regulations • Applications Series Standards, Certifications, and Government Regulations 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 marshal 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 and .2, Canadian Electrical Code C22.1... -
Page 6: Safety Labels And Their Locations
A Clearance Safety Tag (F/N: LL001) is provided with each burner control box (see page 7). Contact Detroit Radiant Products Company or an authorized distributor for obtaining safety signs or replacement labels and tags. - Page 7 4” Black Coated Aluminized For stainless steel upgrades: The combustion tube is 409 Series stainless steel. DESIGN COMPLIES WITH: ANSI Z83.20b-2004-GAS FIRED LOW INTENSITY INFRA-RED HTR. DETROIT RADIANT PRODUCTS COMPANY Serial No.: 0807XXXXXXXXXX 0001 21400 HOOVER ROAD - WARREN, MI (586) 756-0950 www.drp-co.com...
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Page 8: Clearances To Combustibles
Introduction • Clearances to Combustibles Series Clearances to Combustibles WARNING Failure to maintain minimum clearances to combustibles may result in fire and/or explosion, property damage, serious injury, or death. Always maintain minimum clearances and post clearance safety limit signs or the clearance safety tag where needed. - Page 9 Introduction • Clearances to Combustibles Series Chart 1.2 • Clearances to Combustibles in Inches (see Figure 1.2 for Mounting Angles) Sides Mounting Model Number Angle* Front Behind Top** Below HLV-40, HLV-50 [N, P] 0° 45° with 1 side shield 0° with 2 side shields 0°...
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Page 10: Design
Design Pre-Design for Non-Condensing and Condensing Systems The HLV Series vacuum system can be designed as a non-condensing or a condensing system. After reviewing the following pre-design guidelines, proceed to the appropriate section for the desired system. If uncertain as to what type of system should be used, begin by designing for a condensing system (see page 12). -
Page 11: Design For Non-Condensing Systems
Design • Design for Non-Condensing Systems Series Design for Non-Condensing Systems System tube lengths are determined by the gas input (BTU/h) of each burner. Chart 2.1 below indicates system design parameters for each burner model used in each system. When calculating tube lengths, do not add in elbow and tee fittings as they have been accounted for. -
Page 12: Design For Condensing Systems
Design • Design for Condensing Systems Series Design for Condensing Systems System tube lengths are determined by the gas input (BTU/h) of each burner. Chart 2.2 below indicates system design parameters for each burner model used in each system. When calculating tube lengths, do not add in elbow and tee fittings as they have been accounted for. - Page 13 Design • Design for Condensing Systems Series Measure the ‘Calculated Minimum Run’ for each burner. It is generally recommended to shorten runs which exceed the ‘Calculated Maximum Run.’ Refer to Figures 2.2 and 2.3 on page 14 for examples of determining ‘Calculated Maximum Run.’ TEMPERATURE ZONES: In systems where dual zones will be used to control burners on separate thermostats, the following guideline must be met: a) Condensing pipe must begin at the point where two runs (operating on separate zones)
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Page 14: System Design Definitions
Design • System Design Definitions Series System Design Definitions Calculated Maximum Run: The longest allowable ‘Calculated Run’ from each burner to the vacuum pump, including condensing pipe. Calculated Minimum Run: The shortest allowable ‘Calculated Run’ from any burner (including P/N: V-TTS Tandem Tee runs) to the vacuum pump, including condensing pipe. -
Page 15: Typical System Layouts
Design • Typical System Layouts Series Typical System Layouts The following pages illustrate the most common system layouts and their applications. The layouts shown are just a few of many possible designs. A particular application may call for a design that is unique to match its particular building requirements. - Page 16 Design • Typical System Layouts Series Figure 2.7 • Typical Layout D These systems are comonly found in large buildings with long runs where roof penetrations are not desired. They are normally designed for perimeter mounting such as indoor tracks, distribution centers, postal centers, or aircraft hangars.
- Page 17 Design • Typical System Layouts Series Figure 2.8 • Typical Layout E Figure 2.9 • Typical Layout F Typically designed for warehouses, manufacturing This design is often used in service garages plants, or service garages. where an office or storage room exists. Figure 2.10 •...
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Page 18: Vacuum Pump Application
Design • Vacuum Pump Application Series Vacuum Pump Application • The vacuum pump vent length must be between 2 ft. and 25 ft. • The maximum number of elbows allowed in the vent system is two. • Both isolation boots provided with the system must be installed prior to the vacuum pump (see Figure 3.2 on page 21). -
Page 19: Damper Application
Design • Damper Application Series Damper Application A primary damper is provided with every system and is placed before the vacuum pump. Systems with variances in burner gas inputs and/or radiant tube runs will require the placement of secondary dampers* to balance the system’s exhaust flow. NOTE: A maximum of six dampers are allowed in a system. -
Page 20: Installation
Installation • Pre-Installation Series Installation WARNING Improper installation, adjustment, alteration, service, or maintenance can cause property damage, serious injury, or death. Read and understand the installation, operation, and maintenance instructions thoroughly before installing or servicing this equipment. Only trained, qualified gas installation and service personnel may install or service this equipment. -
Page 21: Vacuum Pump Assembly And Mounting
Installation • Vacuum Pump Assembly and Mounting Series Vacuum Pump Assembly and Mounting WARNING Improper suspension of the heating system may result in collapse and being crushed. Always suspend from a permanent part of the building structure that can evenly support the total force and weight of the heater. - Page 22 Installation • Vacuum Pump Assembly and Mounting Series Figure 3.3 • NC-7A Vacuum Pump Mounting Details Chain Hanging Set Safety Chain Primary Damper Vacuum Pump Seam Seam Tube and Reflector Hanger Power Box Figure 3.4 • PB Series Vacuum Pump Mounting Details Threaded Rod Turnbuckle (P/N: V-TB) is (field supplied)
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Page 23: Tube Assembly And Mounting
Installation • Tube Assembly and Mounting Series Tube Assembly and Mounting NOTE: Tube installation begins at the vacuum pump. If installing a condensing system, slope condensing pipe downward from the radiant tube towards the vacuum pump 1/4 in. per 10 ft. as shown in Figure 3.5. Non-condensing systems are mounted level. - Page 24 Installation • Tube Assembly and Mounting Series Figure 3.7 • Attach Tube Clamps NOTE: If the tube clamp comes apart, the spacer must be re-assembled with the spacer’s concave surface facing against Concave surface the radiant tube surface. Tube Clamp IMPORTANT! 150,000 to 200,000 BTU/h models must be installed with a stainless steel tube clamp (P/N: TP-220) located at the seam between the primary combustion chamber and the...
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Page 25: Elbows And Intersections
Installation • Elbows and Intersections Series Elbows and Intersections Elbows and intersections are common components in a tube heater vacuum system. Refer to Chart 3.2 for minimum distance requirements from the burner control box for these accessories. NOTE: Proper tee usage is critical. Refer to the “HLV Packing List” for additional system accessories and options. -
Page 26: Turnbuckle Suspension
Installation • Turnbuckle Suspension Series Turnbuckle Suspension After the first tube run is completely installed (all tubes, clamps, dampers, elbows, intersections, etc.), continue the installation with the run having the next greatest amount of run or condensing pipe. Continue until all runs are complete, ensuring all dampers are properly placed. NOTE: For ease of installation, install reflectors as each tube section is installed. -
Page 27: Baffle Assembly And Placement
Installation • Baffle Assembly and Placement Series Baffle Assembly and Placement All systems include three sections of baffle, having an assembled length of 99 inches. NOTE: In some applications it may be necessary to remove one, two, or all three baffle sections to achieve proper static pressure at the burner box (see page 44). -
Page 28: Reflector Assembly
Installation • Reflector Assembly Series Reflector Assembly Reflectors and reflector accessories direct infrared energy to the floor level. The reflector assembly depends on the heater configuration, proximity to combustibles, and space surrounding the heater. Before you begin assembly, determine if the use of reflector accessories are necessary (see Figure 3.16). - Page 29 ** Refer to the Clearances to Combustibles data found in Chart 1.2 on page 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 Packing List (F/N: LPKHLV) or online at www.detroitradiant.com.
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Page 30: Burner Assembly And Mounting
Installation • Burner Assembly and Mounting 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. -
Page 31: Venting Requirements
Installation • Venting Requirements Series 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. - Page 32 Installation • Venting Requirements Series Figure 3.19 • Horizontal Flue Venting (Preferred) 27/8”1” 24”* If V-CT-H is purchased separately from rest of system, swaged end of damper will FLOW need to be shortened by 2-7/8”. Condensate Condensate Valve Neutralization Tube** Assembly Condensate trap assembly.
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Page 33: Combustion Air Requirements
Installation • Combustion Air Requirements Series 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: •... -
Page 34: Electrical Requirements
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 commonly operates on 120 V, 60 Hz. If an alternate voltage will be used, refer to Chart 3.4 or consult the factory. -
Page 35: Wiring
Installation • Wiring Series Wiring Figure 3.22 • Two Stage System Field Wiring Diagram VACUUM PUMP This shows additional wiring for systems that will CONTROL BOX operate on two temperature zones. NOTE: Do (MOUNTED TO PUMP) not exceed the total number of burners allowed per system as stated in Chart 2.3 on page 18. - Page 36 Installation • Wiring 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 3.24 •...
- Page 37 Installation • Wiring 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 3.25 •...
- Page 38 Installation • Wiring Series Figure 3.26 • Pump and Panel Assembly Internal Wiring NOTE: In North America, the pump and panel are pre-wired at the factory for 120 V unless alternate voltage is ordered. Consult factory with questions. Wiring from the power supply to the panel and pump must be 12 AWG or larger to maintain proper voltage under full load conditions.
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Page 39: Gas Supply
Installation • Gas Supply Series 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, 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”. - Page 40 Installation • Gas Supply 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.
- Page 41 Installation • Gas Supply Series Figure 3.27 • Flexible Gas Connection - Side View Ball Valve / Inlet Tap Adapter Drip Leg/ Sediment Trap 2 in. max displacement 12” Burner Control Box Heater Movement Adapter Flexible Gas Connector Figure 3.28 •...
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Page 42: Operation
Operation • Burner Instructions • Sequence of Operation Series Operation 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. -
Page 43: Thermostat
NOTE: Different thermostats operate according to their particular features. Refer to thermostat specifications for details. HLV Series heaters require a 24 V, two stage thermostat to operate. The burner control box is equipped with a round terminal strip that accepts three (3) 1/4 in. insulated female spade terminals. Do not supply 120 V to the 24 V connection. -
Page 44: System Start-Up Prechecks
Operation • System Start-Up Prechecks • Damper Adjustment 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. •... -
Page 45: Maintenance
Maintenance • Routine Inspection Series Maintenance WARNING Personal injury or death may result if maintenance is not performed by a properly trained gas installer or service personnel. Contact the installer or place of purchase for service. Do not operate heating system if repairs are necessary. Allow heater to cool prior to servicing. -
Page 46: Troubleshooting Guide
Maintenance • Troubleshooting Guide Series Troubleshooting Guide Process Start Corrective Question Question Action Turn up thermostat Find the source of the electrical Find the source of the problem between the thermostat electrical problem transformer, thermostat, and panel. Is the power at the Is the thermostat supplying 24 V Does the exhauster exhauster 120 V/230 V? - Page 47 Maintenance • Troubleshooting Guide Series 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 A faulty relay may exist in the must be replaced.
- Page 48 Maintenance • Troubleshooting Guide Series Continued from page 46 Check to confirm gas pressure is within minimum and maximum Is the ball valve in Does the burner inputs as indicated on the heater’s the ON position? light? rating plate. Is gas pressure OK? Correct problem.
- Page 49 Maintenance • Troubleshooting Guide Series Confirm the flame sensor wire is This model has a flame rod sensor OK and then replace circuit board. located next to the hot surface ignitor. With an amp meter, check the amperage at the flame rod. Is it greater than 7 A? The sensing rod is faulty or the flame is weak.
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Page 50: Replacement Parts
Maintenance • Replacement Parts Series Replacement Parts Figure 5.1 • Burner Assembly NOPS Components 1251 1502 1283 304, 1204 1526A 222A 1250 1280 1229 1297 3072/201B 9 10 1540A/1541A 208A Chart 5.1 • Parts List Part No. Description Part No. Description TP-1 Control Box Cover... - Page 51 Maintenance • Replacement Parts Series Figure 5.2 • Tube and Reflector Components 20C/20D 1516B/1516C/1516D 1215/1255 26A/26C V55A/V56A/V57A 21B/220 1289 V301/V302/V303 V-24 1525 V-D/V-D-SS 1527 1528 V-23 1565 1566 Part No. Description Part No. Description TP-301 Burner Control Box Center Panel TP-1525 Vacuum Exhauster Relay TP-303...
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Page 52: Limited Warranty
Detroit Radiant Products Company’s instructions, or if the serial number has been altered, defaced, or removed. Detroit Radiant Products Company shall not be 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.
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