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Mestek RBS Series Installation And Operation Instructions Manual

Infrared radiant tube heater
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INSTALLATION AND OPERATION INSTRUCTIONS
OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and
understood before installing, operating or servicing this heater.
Single and Two Stage Push Through System (Positive Pressure)
R (B,S,M) S SERIES: (040, 050, 075, 100, 125, 150, 175, 200) – N1/L1/N2/L2
R (B,S,M) U SERIES: (040, 050, 075, 100, 125, 150, 175, 200) – N1/L1/N2/L2
!INSTALLER: This manual is the property of the owner. Please present this manual to the
owner when you leave the job site.
▲WARNING: Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, injury or death. Read the installation, operation and maintenance
instructions thoroughly before installing or servicing this equipment.
IF YOU SMELL GAS:
! DO NOT try to light any appliance.
! DO NOT touch any electrical switch; DO NOT use any
telephone in your building.
! IMMEDIATELY call your gas supplier from a neighbor's
telephone. Follow the gas supplier's instructions. If you
cannot reach your gas supplier, call the fire department.
!IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE.
INFRARED RADIANT TUBE HEATER
FOR YOUR SAFETY
260 North Elm St. • Westfield, MA 01085
Telephone (413) 568-9571 • Fax (413) 562-8437 • www.mestek.com
Models:
DO NOT store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
Mestek, Inc.
Form 43343350
Dec 2017

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Summary of Contents for Mestek RBS Series

  • Page 1 Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department. !IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE. Mestek, Inc. 260 North Elm St. • Westfield, MA 01085 Telephone (413) 568-9571 • Fax (413) 562-8437 • www.mestek.com Form 43343350 Dec 2017...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE 1.0) Safety ..............................2 2.0) Installer Responsibility ........................2 3.0) General Information ........................... 2 4.0) Minimum Clearances to Combustibles ................... 4 5.0) Specifications............................5 6.0) Packing List ............................5 6.1) Accessory Packages ........................11 7.0) Typical Layouts –...

  • Page 3: Safety

    1.0) SAFETY This heater is a self-contained infrared radiant tube heater. Safety information required during installation and operation of this heater is provided in this manual and the labels on the product. The installation, service and maintenance of this heater must be performed by a contractor qualified in the installation and service of gas fired heating equipment.
  • Page 4 Although these heaters may be used in many applications other than space heating (e.g., process heating), Mestek, Inc. will not recognize the warranty for any use other than space heating. For indoor installation only. Not for use in residential dwellings.

  • Page 5: Minimum Clearances To Combustibles

    NFPA54 requires that the installer must post signs that will “specify the maximum permissible stacking height to maintain the required clearances from the heater to combustibles.” Mestek, Inc. recommends posting these signs adjacent to the heater thermostat or other suitable location that will provide enhanced visibility.

  • Page 6: Specifications

    16 ft. * MOUNT HEATERS AS HIGH AS POSSIBLE. Minimums are shown as a guideline for human comfort and uniform energy distribution for complete building heating applications. Consult your Mestek, Inc. representative for the particulars of your installation requirements. Model Identification:...
  • Page 7 BURNER PACKAGE NUMBERS SINGLE STAGE CONTROLS - MESTEK TWO STAGE CONTROLS - MESTEK MODEL NO. PART NO. GAS TYPE MODEL NO. PART NO. GAS TYPE RMS/U040N1U0 44490010 NATURAL RMS/U040N2U0 44490510 NATURAL RMS/U050N1U0 44490030 NATURAL RMS/U050N2U0 44490530 NATURAL RMS/U075N1U0 44490050 NATURAL...
  • Page 8 SINGLE STAGE CONTROLS – BEACON/MORRIS TWO STAGE CONTROLS – BEACON/MORRIS MODEL NO. PART NO. GAS TYPE MODEL NO. PART NO. GAS TYPE RBS/U040N1U0 44492010 NATURAL RBS/U040N2U0 44492510 NATURAL RBS/U050N1U0 44492030 NATURAL RBS/U050N2U0 44492530 NATURAL RBS/U075N1U0 44492050 NATURAL RBS/U075N2U0 44492550 NATURAL RBS/U100N1U0 44492070 NATURAL...
  • Page 9 Systems 60Ft. System 70Ft. System 40 Ft. Pkg 20 Ft. Pkg 40 Ft. Pkg. 30 Ft. Pkg R(B,S,M) S Body Packages – Alumi-Therm/Hot Rolled 44137100 44135010 44137100 44136040 Part # Each Body Package Includes: Qty. Qty. Qty. Qty. 42912169 10 Ft. Tube with 6 Hole Flange (Alumi-Therm) 41932101 10 Ft.
  • Page 10 D. R(B,S,M) U 040-200 Body Package Descriptions (Package Part Number is indicated on the outside of each corresponding carton.) 20Ft. 30Ft. 40Ft. 50Ft. Systems System System System System R(B,S,M) U Body Packages – Aluminized/Hot Rolled or 20 Ft. pkg 30 Ft. pkg 40 Ft.
  • Page 11 E. R(B,S,M) U 040-200 Series Body Package Descriptions – ALC Option (Aluminized Heat Treated) (Package Part Number is indicated on the outside of each corresponding carton.) 20Ft. 30Ft. 40Ft. 50Ft. Systems System System System System R(B,S,M) U Body Packages – Aluminized/Aluminized or 20 Ft.

  • Page 12: Accessory Packages

    6.1) ACCESSORY PACKAGES A. End Reflector Accessory Package, Part #43341000 (1 pkg. per S - Straight Series or 2 pkgs. per U - Series) Contains: End Reflector, #43320000……QTY–2 Speed Clips, #02266010……QTY–8 B. Elbow Accessory Package, Part #43208010 (Option for S - Straight Series Only) Contains: Elbow, #43175000……QTY–1 #10-16 x ½...
  • Page 13 E. U-Bend Reflector Package, Part #43488000 (Option for U - Series Only) Contains: U-Bend Reflector, #43490000……QTY–1 U-Bend End Reflector, #43490050……QTY–1 Speed Clips, #02266010……QTY–11 #10-16 x ½ Self-Drilling Screws, #02189020……QTY–4 Installation Form, #43489000……QTY-1 F. 31” Hanger/Tube Support, Part #43318500 (Option for Angle Mounting of U – Series Only) G.

  • Page 14: Typical Layouts - Straight And U Series

    7.0) TYPICAL LAYOUTS – STRAIGHT AND U SERIES EMITTER LENGTH BODY LENGTH MODEL MODEL Min. Max. Min. Max. R(B,S,M) S 040 10 Ft. 20 Ft. R(B,S,M) U 040 10 Ft. 10 Ft. R(B,S,M) S 050 20 Ft 40 Ft. R(B,S,M) U 050 10 Ft.

  • Page 15: Typical Assembly Layout - Straight Series Shown

    7.1) TYPICAL ASSEMBLY LAYOUT – STRAIGHT SERIES SHOWN Form 43343350 -14- Dec 2017...

  • Page 16: Dimensions - Straight Series

    8.0) DIMENSIONS – STRAIGHT SERIES Typical Dimensions Up to 60 Ft. Shown. Form 43343350 Dec 2017 -15-...

  • Page 17: Dimensions - U Series

    8.1) DIMENSIONS – U SERIES Typical Dimensions Up to 50 Ft. Shown. Form 43343350 -16- Dec 2017...

  • Page 18: Heater Assembly / Joining Of Tube Sections

    8.2) HEATER ASSEMBLY / JOINING OF TUBE SECTIONS Form 43343350 Dec 2017 -17-...
  • Page 19 Form 43343350 -18- Dec 2017...

  • Page 20: Typical Suspension Methods

    6. Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent structure with adequate load capacity. Mestek, Inc. recommends that the body sections be suspended using chains with turnbuckles. This will allow slight adjustments after assembly and heater expansion/ contraction during operation.

  • Page 21: Angle Mounting Of Heaters

    Consult your Mestek Representative if you have any questions prior to the installation concerning particulars of your application.

  • Page 22: Assembly Of Extension Section

    5. Suspend the chain to attach the wire hanger and the tube support bracket. Insert the tube into the wire hanger and then raise the tube support bracket end up to the suspension chain, use “S” hooks to attach the wire hanger and tube support bracket to the chain.
  • Page 23 See typical assembly overview (Section 8.0) for typical complete assembly. Assemble additional extension sections as required for all systems. (See Sections 7.0), and 8.0) for typical layout details.) Join the tube sections together and secure with tube couplings as described below: The following coupling tightening instructions MUST be followed properly to ensure the integrity of the tube connections.

  • Page 24: Inserting Turbulators

    4. Slide the next tube into the coupling. 5. Make sure both tube ends are butted together. 6. Finish tightening both bolts to 40-60 ft.lbs. torque to ensure a complete seal. 7. Use the two Self-drilling screws through the pre-punched holes to secure the tubes in the coupling. 8.

  • Page 25: Adding Reflectors

    MODEL 2 Ft. Turbulator Sections R(B,S,M) S/U 040 R(B,S,M) S/U 050 R(B,S,M) S/U 075 R(B,S,M) S/U 100 R(B,S,M) S/U 125 R(B,S,M) S/U 150 R(B,S,M) S/U 175 R(B,S,M) S/U 200 10.3) ADDING REFLECTORS 1. Slide the reflectors on the tube support/hanger brackets and through the wire hangers. 2.

  • Page 26: Adding Optional 90º Elbow - Straight Seies Only

    11.0) ADDING OPTIONAL 90º ELBOW - STRAIGHT SERIES ONLY 1. The optional 90º elbow must be located a minimum of 10 ft. after the burner box. 2. Hang the body sections in a 90º ("L") shaped pattern. Allow spacing for the elbow. The distance from one end of the elbow to the centerline of the opposite leg is 13"...

  • Page 27: Adding 180º U-Bend - U Series Only

    11.2) ADDING 180º U-BEND - U SERIES ONLY 1. Hang body sections parallel with each other. The centerline distance from tube at each body section should be 18” as shown. 2. Join tube ends of body sections and the U-Bend together and secure with tube couplings as described in Section 10.1).

  • Page 28: Attaching Burner Screen - 200M Btu Models Only

    12.0) ATTACHING BURNER SCREEN – 200M BTU MODELS ONLY A burner screen is assembled with the burner. If necessary, the burner screen must be field adjusted as shown below before operation of the heater. 1. Pull burner screen forward from the gas manifold and slide screen over burner until the tab stops against the rear of the burner cup (approximately 4 - 3/16”...
  • Page 29 The burner box weights 38 lbs. Use caution when handling it. Failure to install the burner box in an upright position and lights facing the floor will void the manufacturer’s warranty. Form 43343350 -28- Dec 2017...

  • Page 30: Connecting The Tiss System

    12.2) CONNECTING THE TISS SYSTEM Description: The TISS (Tube Integrity Safety System) is designed to shut the main burner off in the event that a burnout occurs in the first 10ft. section of firing tube. Note: When replacing the firing tube a new TISS wire assembly PN 44176510 (spring and spring retainer clamp not included) must also be installed.
  • Page 31 3. Hold the spring retainer clamp and pull the TISS wire assembly to end of reflector at overlap joint. Slide spring retainer clamp over end of reflector as shown. Step 3 4. After attachment of the TISS, check to make sure that there is sufficient tension on the wire. Follow the diagram below to increase or decrease the tension as necessary.
  • Page 32 ANGLE MOUNTED HEATERS ONLY 5. If heaters are to be angle mounted, the TISS wire holder clamp must first be re-positioned as shown using the bottom hole pattern of the clamp. Follow procedures described earlier for all other adjustments. Step 5 Failure to re-position the wire clamp at the bottom hole pattern will shorten the life expectancy of the TISS wire assembly.

  • Page 33: Gas Connections And Regulations

    13.0) GAS CONNECTIONS AND REGULATIONS IMPORTANT BEFORE CONNECTING THE GAS TO THE HEATER 1. Connect to the supply tank or manifold in accordance with the latest edition of National Fuel Gas Code (ANSI Z223.1), and local building codes. Authorities having jurisdiction should be consulted before the installation is made.
  • Page 34 US ONLY: Connector MUST be installed in “” configuration. Use only the 36” long connector that was furnished with this heater. US ONLY: A gas connector certified for use on a tubular type infrared heater per the standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 is supplied for installation in US only.

  • Page 35: Instructions For Pressure Test Gauge Connection

    14.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION SUPPLY PRESSURE 1. The installer will provide a 1/8” N.P.T. tapped plug, accessible for test gauge connection immediately upstream of the gas supply connection to the heater. OUTLET GAS PRESSURE CHECK AND ADJUSTMENTS Gauges that measure pressure in pounds per square inch are not accurate enough to measure or set the manifold pressure.
  • Page 36 Figure 1 TO ADJUST REGULATOR (two stage gas valves): Turn on power and energize main gas valve solenoid. Do not energize the HI solenoid. Remove regulator cover screw from the low outlet pressure regulator (see Figure 2 below) and turn screw ...

  • Page 37: Electrical Thermostat Connections

    GAS PRESSURE TABLE SUPPLY PRESSURE MANIFOLD PRESSURE GAS TYPE High Low (2-stage only) Minimum* Maximum Natural Gas 3.5” W.C. 1.4” W.C. 5” W.C. 14” W.C. Propane Gas 10.0” W.C. 4.0” W.C. 11” W.C. 14” W.C. * Minimum permissible gas supply pressure for purpose of input adjustment. 7”...

  • Page 38: Single Stage (N5/L5) Internal And Thermostat Connections

    15.1) SINGLE STAGE (N5/L5) INTERNAL AND THERMOSTAT CONNECTIONS SINGLE STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM SINGLE STAGE CONTROLS - SCHEMATIC WIRING IGNITION MODULE TERMINAL DESIGNATIONS DIAGRAM 24VAC/R 24 VAC Supply to Module TH/W Thermostat Input PS/W Pressure Switch Input System Ground Valve Power Valve Ground...
  • Page 39 SINGLE STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS SINGLE STAGE CONTROLS A. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – SINGLE HEATER B. LINE VOLTAGE (120V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS Form 43343350 -38- Dec 2017...

  • Page 40: Two Stage (N7/L7) Internal And Thermostat Connections

    C. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATERS D. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS (utilizing a fan center relay) 15.2) TWO STAGE (N7/L7) INTERNAL AND THERMOSTAT CONNECTIONS TWO STAGE CONTROLS - INTERNAL CONNECTION WIRING DIAGRAM Form 43343350 Dec 2017 -39-...
  • Page 41 TWO STAGE CONTROLS - SCHEMATIC WIRING IGNITION MODULE TERMINAL DESIGNATIONS DIAGRAM 24VAC/R 24 VAC Supply to Module TH/W Thermostat Input PS/W Pressure Switch Input System Ground Valve Power Valve Ground 120/240 VAC Input (Hot) Blower Output TWO STAGE CONTROLS - THERMOSTAT WIRING DIAGRAMS TWO STAGE CONTROLS Form 43343350 -40-...
  • Page 42 A. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATERS B. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – MULTIPLE HEATERS Form 43343350 Dec 2017 -41-...

  • Page 43: Venting

    C. LOW VOLTAGE (24V) 3 WAY MANUAL SWITCH CONNECTIONS – MULTIPLE HEATERS 16.0) VENTING This is a category lll appliance. A. BASIC FLUE VENTING — Venting must comply with the latest edition of the National Fuel Gas Code (ANSI Z223.1-latest edition) or the authority having jurisdiction. Other venting references are in the equipment volume of the ASHRAE Handbook.
  • Page 44 Heat Maximum Fresh air Max. combination of Maximum vent length ft. Model exchanger intake length ft (4” fresh air and vent ft. (4” diameter) length ft diameter) (4” diameter) R(B,S,M) S/U 040 R(B,S,M) S/U 040 R(B,S,M) S/U 050 R(B,S,M) S/U 050 R(B,S,M) S/U 050 R(B,S,M) S/U 075 R(B,S,M) S/U 075...
  • Page 45 8. Single-wall metal pipe shall not originate in any unoccupied attic or concealed space and shall not pass through any attic, inside wall or concealed space, or through any floor. For the installation of a single-wall metal pipe through an exterior combustible wall, refer to latest edition of the National Fuel Gas Code or the authority having jurisdiction.
  • Page 46 MULTIPLE HEATER VENTING (CONNECTIONS INTO A COMMON VENT OR MANIFOLD) Requirements for venting of multiple heaters are the same as described for SINGLE HEATER VENTING except as follows: 1. The common vent size and total vent height is normally determined by the number of heaters per common vent, length of horizontal connector runs, and connector fall.
  • Page 47 Multiple Heater Vertical Venting Arrangement Multiple Heater Horizontal Venting Arrangement VENT SIZING TABLE — Multiple Heater Venting Number of Heaters Horizontal and vertical Vertical Only R(B,S,M) S/U 040 4” 4” 4” 4” R(B,S,M) S/U 050 4” 4” 4” 5” R(B,S,M) S/U 075 4”...

  • Page 48: Air For Combustion

    B. INDIRECT VENTING (UNVENTED HEATERS) — This heater requires ventilation in the building to dilute the products of combustion and provide fresh air for efficient combustion. Where unvented heaters are used, gravity or mechanical means shall be provided to supply and exhaust at least 4 CFM per 1,000 Btu/hr input of installed heaters.
  • Page 49 In multiple heater applications, the combustion air intake may be ducted individually or common ducted in the same configuration as shown for venting in Section 16.0). For combustion air intake duct sizing, please refer to the Vent Sizing Table and use the diameter indicated, based on the number of heaters per duct. All vent terminations and Combustion Air Intake Terminations must be at least 6”...

  • Page 50: Lighting And Shutdown Instructions

    18.0) LIGHTING AND SHUTDOWN INSTRUCTIONS 1. Turn on the gas and electrical supply. 2. Set the thermostat to call for heat. The blower motor will energize. 3. Ignition should occur after the 15-second pre-purge. 4. If the burner fails to light, or flame is not detected during the first trial for ignition (a period of approximately 15 seconds) the gas valve is de-energized and the control goes through an inter-purge delay of approximately 60 seconds before another ignition attempt.
  • Page 51 Note: When the tube heater is operated by a thermostat interrupting the line voltage (120V) to the heater then the post purge function is disabled. If the flame is not sensed during sequence T3 then the burner will automatically begin re-ignition sequence T2. The ignition sequence will be repeated three times with a 60 second inter-purge.

  • Page 52: Control Component Location

    20.0) CONTROL COMPONENT LOCATION Form 43343350 Dec 2017 -51-...

  • Page 53: Cleaning And Annual Maintenance

    21.0) CLEANING AND ANNUAL MAINTENANCE This heater must be cleaned and serviced annually by a qualified contractor before the start of each heating season and at any time excessive accumulation of dust and dirt is observed. Maximum heating efficiency and clean combustion will be maintained by keeping the heater clean.

  • Page 54: Troubleshooting Guide - Single Stage (N1/L1)

    22.0) TROUBLESHOOTING GUIDE – SINGLE STAGE (N1/L1) Form 43343350 Dec 2017 -53-...
  • Page 55 TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) Form 43343350 -54- Dec 2017...
  • Page 56 TROUBLESHOOTING GUIDE – SINGLE STAGE (CONTINUED) Form 43343350 Dec 2017 -55-...

  • Page 57: Troubleshooting Guide - Two Stage (N2/L2)

    22.1) TROUBLESHOOTING GUIDE – TWO STAGE (N2/L2) Form 43343350 -56- Dec 2017...
  • Page 58 TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43343350 Dec 2017 -57-...
  • Page 59 TROUBLESHOOTING GUIDE – TWO STAGE (CONTINUED) Form 43343350 -58- Dec 2017...

  • Page 60: Replacing Parts

    23.0) REPLACING PARTS Only use genuine Mestek, Inc. replacement parts. Parts are available from the factory for replacement by a licensed person. Refer to the Replacement Parts Guide in Section 25.0) for all replacement parts. 23.1) REMOVAL OF MAIN BURNER AND ELECTRODES The main burner can be inspected without removing the burner housing from the heat exchanger tube.

  • Page 61: Removing Gas Valve And Manifold Assembly

    23.2) REMOVING GAS VALVE AND MANIFOLD ASSEMBLY 23.3) AIR SWITCH PRESSURE CHECK Form 43343350 -60- Dec 2017...

  • Page 62: Ignition System Checks

    1. Open hinged access panel. 2. Add tubing to connect the air switch tubing P1 + and P2 - with the connector tees and the probes P1+ and P2+. 3. Connect plastic tubing of a digital or inclined water manometer with a 0-2” scale onto the connector tees. 4.

  • Page 63: Installation Data

    IGNITION MODULE DIAGNOSTICS Flame Fault If at any time the main valve fails to close completely and maintains a flame, the full time flame sense circuit will detect it and energize the combustion blower. Should the main valve later close completely removing the flame signal, the combustion blower will power off following the post purge period.

  • Page 64: Replacement Parts Guide

    25.0) REPLACEMENT PARTS GUIDE BURNER BOX Item No. Part No. Description Qty. Fasteners 02295040 PHTCS #6-32 x 3/8" 02266010 Speed Clips (for air inlet plate) 02261030 HHTCS #8-32 x 3/8" (green coated) 02242050 PHTCS #8-32 x 3/8" 02242070 PHTCS #8-32 x 1/2” 02123170 RHMS #8-32 x 3/4"...
  • Page 65 30186270 Air Switch (set point @ .34”WC, GREEN LABEL) 125/150/175/ 200 mbh Labels/Manual 42848220 Label, Nameplate - Sterling 1-Stage 42848221 Label, Nameplate – Mestek 1-Stage 42848222 Label, Nameplate – Beacon 1-Stage 42848230 Label, Nameplate - Sterling 2-Stage 42848231 Label, Nameplate – Mestek 2-Stage 42848232 Label, Nameplate –...
  • Page 66 Form 43343350 Dec 2017 -65-...
  • Page 67 ALL ILLUSTRATIONS ARE INTENDED TO GIVE THE GENERAL IMPRESSION OF UNITS ONLY. OTHER COMBINATIONS OF 5 FT. AND 10 FT. SECTIONS, AND ONES WITH OR WITHOUT THE ELBOW PACKAGE ARE POSSIBLE. PLEASE CONSULT WITH YOUR Mestek, Inc. SALES REPRESENTATIVE. WE RESERVE THE RIGHT TO ALTER ANY SPECIFICATION WITHOUT NOTICE. Form 43343350...

  • Page 68: Warnings Card

    26.0) WARNINGS CARD Copies of this card may be ordered at no charge under part no. 43344970 for installation near the heater. Form 43343350 Dec 2017 -67-...

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