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Installation, Operation,
Maintenance and Parts Manual
CE Certified: 230V-50Hz (G20, G25, G25.3, G31) Infra-Red Tube Heater.
The AK-HL Series Infra-Red Tube Heater is a positive pressure, dual-stage radiant heater
system (AK-DX is a single stage model). All persons involved with the installation, operation
and maintenance of the heater system must read and understand the information in this
manual.
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 and/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.
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.
Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department
Version: January 2017
AK-HL Series
(Including AK-DX 50 model)
WARNING
Keep these instructions for future reference
1
manual number: 0009 0000EN
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Related Manuals for Alke AK-HL Series
Summary of Contents for Alke AK-HL Series
- Page 1 Maintenance and Parts Manual CE Certified: 230V-50Hz (G20, G25, G25.3, G31) Infra-Red Tube Heater. The AK-HL Series Infra-Red Tube Heater is a positive pressure, dual-stage radiant heater system (AK-DX is a single stage model). All persons involved with the installation, operation and maintenance of the heater system must read and understand the information in this manual.
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Page 2: Table Of Contents
21m (70-kit) Titanium & Aluminized Aluminized or HRT Note: HRT = Hot rolled tubes *) This model is the single stage equivalent of the AK-HL series. Only the low burner function is eliminated. Version: January 2017 manual number: 0009 0000EN... -
Page 3: Ak-Hl Series Technical Specification
1.0 AK-HL Series Technical Specifications Chart 1.2: AK-HL Series Technical Specifications High Rate Proving Model Injector Inlet Air Inlet Min Gas Max. Gas Burner Rate (input) type Injector Marking Orifice Marking Pressure Pressure Pressure Pressure Baffle length by Model length (m) Point (“) -
Page 4: Safety
2.0 Safety The intent of this manual is to provide information regarding general safety, installation, operations and maintenance of this tube heater. You must read and understand all instructions and safety warnings before installing or servicing the tube heater. Warning Improper installation, adjustment, alteration, service or maintenance can cause property damage, serious injury or death. -
Page 5: Codes And Regulations
2.3 Codes and Regulations The following must be reviewed before installing this heater: Check the heater rating label on the heater to verify the proper gas to be used. Check other labels on the heater to verify proper mounting and clearance to combustibles. ... -
Page 6: Clearances To Combustibles
2.4 Clearance to Combustibles Warning Fire Hazard Always maintain published clearance to combustibles. Failure to comply with the stated clearances to combustibles may result in personal injury, death and/or property damage. Warning This is not an explosion-proof heater. Do not store or use flammable objects, liquids or vapor in the vicinity of the heater. - Page 7 Check the rating plate on the heater to verify the minimum clearances to combustibles and gas type for your model heater. AK-HL Series Clearance to Combustibles (cm) Chart 2.1: Clearance to Combustibles Model No. Mounting...
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Page 8: Installation
3.0 Installation 3.1 Design Consideration and Prechecks Warning Improper installation, adjustment, alteration, service, or maintenance can cause property damage, serious injury, or death. Read and understand the installation, operating, 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 9 Chart 3.1 Recommended Mounting Heights 15 kW 3.0 to 4.6 6.1 x 3.7 3.7 x 3.7 3.0 to 6.1 6.1 to 12.2 20-25 kW 3.3 to 6.1 6.7 x 4.6 6.1 to 9.1 9.1 to 15.2 15 kW 3.0 to 5.5 9.2 x 4.3 5.2 x 4.0 3.0 to 6.1...
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Page 10: Design Scenarios
3.2 Design Scenarios A tube heater system is being installed in 27.4m (L) x 15.2m (W) space with 4.3m ceiling. Two overhead doors are located at one end and an equipment storage area exists on one side. The calculated heat load is 88 kW. Figure 3.2 –... -
Page 11: Hanger Placement And Suspension
3.3 Hanger Placement and Suspension Warning Improper suspension of the heater may result in collapse and being crushed. Always suspend the appliance from a permanent part of the building structure that can support the total weight and force of the heater Warning Failure to maintain the published clearance to combustibles may result in fire and/or explosion, property damage, serious injuries or death. - Page 12 NOTE: A sticker identifying the combustion chamber is located in the swaged end of the tube. Figure 3.4 Heater Suspension Layout 1 = Suspension points 2 = Burner box 3 = Burner tube 4 = Ignitor/sensor box 5 = 3m Primary combustion chamber (material can vary depending model, see page 2) 6 = Tube clamp (on 44-50 kW models the second clamp must be Stainless Steel) 7 = Radiant Emitter Tube (On 44-50 kW models the second tube is an Aluminized secondary combustion chamber)
- Page 13 Suspension of the heater must conform to applicable codes referenced in the safety sections of the applicable standards and these instructions. 3. Prepare the mounting surface, if necessary such as: weld blocks, drill holes. Figure 3.5 NOTE: The burner control box and the radiant tubes should be in a straight alignment and level.
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Page 14: Radiant Tube Assembly
3.4 Radiant Tube Assembly To install the radiant tubes: 1. Place tubes in hangers with the welded seam facing downward and the swaged end of the tube towards the exhaust end of the heater system (see Figure 3.6) Refer to section 3.8 on page 21 for tube installation sequence. Figure 3.6 Attach Hangers 1 = Hanger 3 = Swaged end... -
Page 15: Optional U-Band Or Elbow Accessory Configuration
3. Slip-fit the radiant tube sections together until tightly connected (install swaged end of each tube towards exhaust end). NOTE: If it is difficult to mate the tubes, they may be installed incorrectly. 4. Center tube clamps over the seams where two radiant tube sections connect. If necessary, rotate tube clamps so they will not interfere with the reflector end caps during expansion and contraction of the heater while operating. - Page 16 NOTE: we advice for the 9m, 15m and 21m models to use the 5 EA – SUB accessory package when installing in a “U” configuration. Figure 3.10 U – Tube Hanger Mounting Options SMB = Single mounting bracket 1 = Exhaust end 2 = Brass knuckle U –...
- Page 17 Figure 3.12 Elbow and U–Bend Clearances 1 = Tube clamps 2 = U-bend/Elbow can be set in both directions Figure 3.13 U–Bend and Elbow Dimensions Dimensions: TF1B Dimensions: E6 Chart 3.4: Overall Dimensions for Heaters Chart 3.3: Minimum Distance from Burner Control Box to U –...
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Page 18: Burner Control Box Suspension
3.6 Burner Control Box Suspension Suspending the burner control box must be done in accordance with the applicable codes listed in the safety section of the applicable standards and these instructions. The burner control box must be in straight alignment with radiant tubes and level. 1. -
Page 19: Reflector Assembly
3.7 Reflector Assembly To install the reflectors: 1. Attach reflector center supports onto radiant tubes. 2. Slide each reflector section through the hangers and adjust the reflector tension spring into the V–groove on the top of the reflector. The reflectors should overlap approximately 10 cm. - Page 20 Chart 3.5: Common Optional Accessories Reflector Accessories Description Part # Elbow Reflector* 90° bend, highly polished aluminium reflector elbow. Designed to fit atop one elbow accessory fitting. U-Reflector* 180° bend, highly polished aluminium reflector U- bend. Designed to fit atop one U-bend accessory fitting.
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Page 21: Baffle Assembly And Placement
3.8 Baffle Assembly and Placement NOTICE Different inputs and models utilize different baffle lengths. Remove all enclosed baffle sections from box and retain with applicable heater. Reference shipping label or dataplate on the heater or the table on page 3 for the proper baffle size. Burner control box Each 84 cm baffle section must be assembled with with Burner tube... - Page 22 To assemble the baffles: NOTE: Baffles may be inserted into the tube while being assembled. 1. Determine the number of baffles needed for your model number. Remove one 84 cm baffle section if heater is installed with an elbow or U-bend accessory. 2.
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Page 23: Flueing Requirements
3.9 Flueing requirements Warning Insufficient ventilation and flueing and/or improperly sealed flues may release gas into the building which could result in health problems, carbon monoxide poisoning or death. Improper flueing may result in fire, explosion, injury or death. Seal flue pipes with high temperature sealant and three (3) sheet metal screws incase the flue system does not incorporate a rigid fixing method. - Page 24 Sidewall (Horizontal) Flueing Guidelines: To prevent moisture from entering the heater system, slope the flue pipe down toward the outlet 20 mm per meter of flue length. Do not pitch the heater. Flue must extend beyond any combustibles overhang. Figure 3.21 Vent Slope –...
- Page 25 Flue Termination Always follow the local requirements incase they deviate from the info below. Flue must terminate a minimum of 1,2m below, 1,2m horizontally from and 0,3m above any window or door that may be opened and gravity air inlet into the building. ...
- Page 26 Optional Unflued Operation Warning Not for residential use. The use of unflued tube heaters in residential indoor spaces may result in property damage, serious injury or death. Use unflued operation in commercial and industrial installations with proper ventilation rates only. When installing in an un-vented configuration: ...
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Page 27: Combustion Air Requirements
3.10 Combustion Air Requirements NOTICE This heater has a factory preset air orifice for proper combustion air supply. If combustion air is to be provided for a tightly closed area, 440 mm2 of free air opening must be provided for each kW of heater input. Non-contaminated air for combustion must be deducted to the heater if chlorinated or fluorinated contaminants, high humidity and other contaminants such as sawdust or welding smoke are present in the area where the heater is installed or if the building has a... - Page 28 Guidelines: Chart 3.6: Limitations for length and size of combustion air intake duct Single Heater Intake Dual Heater Intake Air intake pipe size Max. Intake Length Air intake pipe size Max. Intake Length 100mm 6,1m 150mm 6,1m 130mm 9,2m 200mm 9,2m 150mm 12,2m...
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Page 29: Gas Supply And Pressure
3.11 Gas Supply and Pressure 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. Important! Before connecting the gas supply to the burner control box: ... - Page 30 Adjusting Burner Pressure Remove the lid to the valve compartment. Open the pressure nipple and connect pressure meter tube. Remove the cap over the adjusting screws on the gas valve pressure regulator. Place a 10mm spanner (wrench) on the outer adjusting nut and a screwdriver on the black inner screw.
- Page 31 Warning Failure to install, operate or service this appliance in the approved manner may result in property damage, injury or death. Only trained, qualified gas installation and service personnel may install or service this equipment. To connect the gas: This heater must be installed and service by trained gas installation and service personnel only.
- Page 32 5) Final assembly must be tested for gas leaks according local codes. IMPORTANT: Before installation, check that local distribution conditions, nature of gas and pressure, and the adjustment of the appliance are compatible. 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.
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Page 33: Electrical Requirements
3.12 Electrical Requirements Verify that the heaters voltage (as listed on the rating plate) matches that of your application. Heaters operate on 230 volts, 50 Hz, single phase. The amperage requirement is 4,8 Amp starting current and 0.6 Amps running current per heater. ... - Page 34 Internal Wiring Diagrams If any of the original wire as supplied with this appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C. Figure 3.34 – Internal Wiring Diagram (AK-DX) Figure 3.35 –...
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Page 35: Operation
Operation Warning This heater is not equipped with a pilot ignition system. Do not attempt to light system manually. Commissioning Procedures: 1. Ensure that ball valve to the heater is turned “OFF” 2. Purge air from the gas supply line and test for gas soundness in accordance with the relevant Standards. -
Page 36: Maintenance
5.0 Maintenance Warning Only a qualified installer should conduct service and/or maintenance. Use protective glasses when cleaning or servicing the heater. Disconnect power to heater before servicing. Do not operate unit if repairs are necessary. Allow heater to cool prior to servicing. -
Page 37: Troubleshooting Guide
5.1 Troubleshooting Guide NOTE: Contact appliance manufactured prior to replacing parts other than those specified in this manual Chart 5.2 Troubleshooting Guide Symptom Possible Cause Corrective Action Thermostat closed, fan doesn’t Blow fuse Replace Faulty thermostat Replace operate ... -
Page 38: Parts
6.0 Parts Figure 6.1 Burner Assembly Components Chart 6.1 AK-HL Series Parts List Part # Description Part # Description TP-1 Control Box Cover TP-65I Interlocking 838mm Baffle Section TP-5 Flange Gasket TP-68B 1/2" Strain Relief Bushing TP-9A Conduit Coupling TP-70^... -
Page 39: Tube And Reflector Components
Part # Description Part # Description TP-217 Pressure Barb Fitting TP-640B SIT-SIG 843 Gas Valve Assembly TP-220 101 mm Stainless Steel Tube Clamp TP-646A AC Rectifier Cord TP-221 Igniter Mounting Bracket Gasket TP-650 12kv High Temperature Lead /w Rubber Boot TP-223 Gas Manifold TP-656A... -
Page 40: Ak-Hl Series Kit Contents
Refer to the chart below for a list of the kit contents for your model heater. Materials not included in the kit (e.g. sheet metal screws, vent material, terminals, etc) are the responsibility of the installer. Kit Contents for AK-HL Series – Reference the column for your model TP-19B Hanger with TP-82 Reflector Center...
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