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.
HLV Series Table of Contents Contents 1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HLV Series Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Approvals Standards and Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Labels and Locations . . . . . . . . . . . .
HLV Series 1.0 Introduction • Overview • System Components 1.0 Introduction Overview The intent of this manual is to provide information regarding general safety, installation, operation and maintenance of the tube heater vacuum system. You must read, and understand, the instructions and safety warnings in this manual before installing the heating system. System Components* Prior to installation, verify that the heater’s gas type and voltage (as listed on the rating plate) match that of your application.
HLV Series 1.0 Introduction • HLV Series Specifications Specifications Chart 1.1 • HLV Series Specifications Approximate System Hanging Weights Per 10 Ft. Per 10 Ft. Radiant Pipe Tailpipe & & Reflector Reflector Section Section Typical Combustion Mounting Chamber Height^ (Black Coated) Radiant Emitter Tube(s)** BTU/H BTU/H Per Burner Head N or P 40,000 40,000 35 lbs. 35 lbs. 45 lbs. 9’ to 14’ Al-Ti Coated Alum or 304 Stainless Uncoated HRT Steel HLV-50* N or P 50,000 50,000 35 lbs.
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 and .
HLV Series 1.0 Introduction • Safety Labels and Locations Read and understand all safety information and warnings in this manual before installation, operation and maintenance of the radiant tube heater system. Safety Labels and Their Locations Safety warning labels must be maintained on the heating system. Safety labels and their locations are illustrated below and on page 7. Product safety signs or labels should be replaced by the product user when they no longer are legible.
HLV Series 1.0 Introduction • Safety Labels and Locations SAMPLE Air Metering Orifice DO NOT REMOVE HOT 120V TP-114 TP-3014 F/N: LLAC Air Metering Orifice 3” Back Panel NEUTRAL EARTH ® RE-VERBER-RAY INFRA-RED RADIANT TUBE HEATER FOR OUTDOOR USE AND INDOOR (Non-Residential) INSTALLATION ONLY. Class IIIA Permanent Label HOT 120V NEUTRAL EARTH - 120V HEATER INPUT - MODEL NO.
HLV Series 1.0 Introduction • Clearance to Combustibles Clearance to Combustibles ! WARNING Failure to maintain minimum clearance 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. Clearance to combustibles is defined as the minimum distance that must exist between the tube surface, or reflector, and any combustible items (see Figure 1.2).
HLV Series 1.0 Introduction • Clearance to Combustibles Chart 1.2 • Clearance to Combustibles in Inches (see Figure 1.2 for Mounting Angles) Model Number Mounting Angle* Sides Front HLV-40, HLV-50 [N, P] Behind Top** Below 0° 9 9 4 47 45° 39 8 10 47 with 1 side shield 0° 29 8 4 47 with 2 side shields 0° 9 9 4 47 20 ft. from burner 0° 7 7 4 30 HLV-60, HLV-75 [N, P] 0° 9 9 4 48 45° 39 8 10 48 with 1 side shield 0° 29 8 4 48 with 2 side shields 0° 9 9 4 48 20 ft.
HLV Series 2.0 Design • Pre-Design 2.0 Design Pre-Design for Condensing and Non-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 it is uncertain as to what type of system should be used, begin by designing for a condensing system, p.12.
HLV Series 2.0 Design • Design for Non-Condensing Systems 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. Designing a non-condensing system can be fairly straightforward given the following steps are read carefully.
HLV Series 2.0 Design • Design for Condensing Systems 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. Designing a condensing system can be fairly straightforward given the following steps are read carefully.
HLV Series 2.0 Design • Design for Condensing Systems 4 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 & 2.3 on p.14 for examples of determining ‘Calculated Maximum Run’.
HLV Series 2.0 Design • System Design Definitions System Design Definitions Calculated Maximum Run: The longest allowable ‘Calculated Run’ from any burner to the vacuum pump, including condensing pipe. Calculated Minimum Run: The shortest allowable ‘Calculated Run’ from any burner (including V-TTS Tandem Tee runs) to the vacuum pump, including condensing pipe.
HLV Series 2.0 Design • Typical System Layouts Typical System Layouts The following pages illustrate the most common system layouts and their applications. The layouts shown are just a few of many designs. A particular application may call for a design that is unique to match its’ particular building requirements. In any case, these layouts should serve as a starting point for the design in many applications. NOTE: Figures 2.4 - 2.
HLV Series 2.0 Design • Typical System Layouts Figure 2.7 • Typical Layout D These systems are typically found in large buildings with long runs where roof penetrations are not desired. These layouts are normally designed for perimeter mounting such as indoor tracks, distribution centers, postal centers or aircraft hangars.
HLV Series 2.0 Design • Typical System Layouts Figure 2.8 • Typical Layout E Figure 2.9 • Typical Layout F Typically designed for warehouses, manufacturing plants or service garages. This design is typical in service garages where an office or storage room exists. Figure 2.10 • Typical Layout G Designed for bus garages, large service garages or large fire stations.
HLV Series 2.0 Design • Vacuum Pump Application Vacuum Pump Application • The vacuum pump vent length must be from 2 ft. to 25 ft. • The maximum number of elbows in the vent system is two. • Both isolation boots provided with the system must be installed prior to the vacuum pump (Figure 3.2). Vacuum pump selection is based on the overall BTU/H input of each system. Refer to Chart 2.3 for vacuum pump determination.
HLV Series 2.0 Design • Damper Application Damper Application A primary damper is provided with every system which 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. Refer to Figures 2.12 - 2.14 for examples of damper placement. Figure 2.
HLV Series 3.0 Installation • Pre-Installation 3.0 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.
HLV Series 3.0 Installation • Vacuum Pump Assembly and Mounting 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. Prior to mounting the vacuum pump, ensure the building structure and support brackets have adequate load characteristics to support the pump. Refer to Chart 3.1 below.
HLV Series 3.0 Installation • Vacuum Pump Mounting Vacuum Pump Mounting Figure 3.3 • NC-7 Vacuum Pump Mounting Details Chain Hanging Set Safety Chain Primary Damper Vacuum Pump Seam Seam Tube and Reflector Hanger Power Box Figure 3.
HLV Series 3.0 Installation • Tube Assembly and Mounting • Hanger Placement Tube Assembly and Mounting Tube installation begins at the vacuum pump: 1 If installing a condensing system, slope condensing pipe upward from the vacuum pump 1/4 in. per 10 ft. as shown in Figure 3.5. Non-condensing systems are mounted level. Figure 3.5 • Condensing Pipe Suspension Turnbuckles (P/N: V-TB) are recommended for all condensing pipe suspension points for ease of slope adjustment.
3.0 Installation • Tube Assembly and Mounting • Tube Clamps HLV Series Figure 3.7 • Attach Tube Clamps Concave surface NOTE: If the tube clamp comes apart, the spacer must be re-assembled with the spacer’s concave surface facing against the radiant tube surface.
HLV Series 3.0 Installation • Tube Assembly and Mounting • Common Accessories 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 Series Accessory Book for additional system accessories and options. Figure 3.
HLV Series 3.0 Installation • Tube Assembly and Mounting • 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 - ensure all dampers are properly placed. NOTE: For ease of installation, install reflectors as each tube section is installed.
HLV Series 3.0 Installation • Tube Assembly and Mounting • Baffle Assembly and Placement 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 (P. 44). Consult factory. 1 2 Orient the baffle tabs at a 90° angle to the baffle keyhole (Figure 3.12).
HLV Series 3.0 Installation • Reflector Assembly 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 (P. 29). To install the reflectors (Figure 3.14): 1 Attach the reflector center supports onto radiant tubes at the halfway point between hangers.
HLV Series 3.0 Installation • Reflector Assembly • Common Reflector Accessories Figure 3.15 • Common Reflector Accessories U-shaped Reflector* (P/N: RU) Highly polished aluminum reflector used over a 180° U-bend accessory fitting. Elbow Reflector* (P/N: RE) Highly polished aluminum reflector used over an E6 90° elbow accessory fitting. Tee Reflector (P/N: V-RTE) Highly polished aluminum reflector used to cover a V-T or V-TI tee fitting.
HLV Series 3.0 Installation • Burner Assembly and Mounting 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.
HLV Series 3.0 Installation • Venting Requirements Flue Venting ! 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.
HLV Series 3.0 Installation • Venting Requirements Figure 3.18 • Horizontal Flue Venting (Preferred) Vacuum Pump A storm collar is recommended to prevent drippage back flow. *It is recommended to extend at least 24 in. past building to avoid potential building discoloration. Horizontal venting must slope downward 1/4 inch per foot. 24”* Adhere to local codes for condensate disposal. Isolation Boot Condensate trap assembly.
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.
HLV Series 3.0 Installation • Electrical Requirements • Electrical Data 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.
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) 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.
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.
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.
HLV Series 3.0 Installation • Electrical Requirements • Pump & Panel Wiring 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.
HLV Series 3.0 Installation • Gas Supply 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”.
HLV Series 3.0 Installation • Gas Supply ! 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.
HLV Series 3.0 Installation • Gas Supply Figure 3.26 • Flexible Gas Connection • Side View Ball Valve / Inlet Tap Adapter Drip Leg/ Sediment Trap 2 in. max displacement 12” Adapter Burner Control Box Heater Movement Flexible Gas Connector Figure 3.27 • Flexible Gas Connection • Rear View Ball Valve / Inlet Tap Flexible Gas Connector 45° 45° Horizontal Burner Control Box Remove cap to clean sediment trap NOTE: Do not exceed 14 Inches W.C. to the appliance.
4.0 Operation • Lighting and Shutdown • Sequence of Operation HLV Series 4.0 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. 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).
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.
HLV Series 4.0 Operation • System Start-Up and Damper Adjustment 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.
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.
HLV Series 5.0 Maintenance • Troubleshooting Guide HLV Series Troubleshooting Guide Turn up thermostat Find the source of the electrical problem between the thermostat transformer, thermostat and panel.
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.
HLV Series 5.0 Maintenance • Troubleshooting Guide Continued from page 46 Does the burner light? No Is the ball valve in the ON position? Check to confirm gas pressure is within minimum and maximum inputs as indicated on the heater’s rating plate. Is gas pressure OK? Yes Yes No No Yes Correct problem. Does the burner stay on? No Correct problem. Purge gas lines of air.
HLV Series 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. 5.0 Maintenance • Troubleshooting Guide Yes Confirm the flame sensor wire is OK and then replace circuit board. Is it greater than 7 amps? 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.
HLV Series 5.0 Maintenance • Parts • Heater Burner Assembly Components Replacement Parts Figure 5.1 • Burner Assembly Components 70 832 1 NOPS 219 207 1502 828 218 301 825 1229 14 15 16 17 1251 329 21B 97 1283 304, 1204 1526A 31B 13 68A 217 5 1297 1250 1280 321 221 222 222A 11 214 13 200A/201B 114 33B 31B 212 333 85 83 223 76 204 12 1540A/1541A 84 9 10 208A 303 Chart 5.1 • Parts List Part No. Description Part No.
HLV Series 5.0 Maintenance • Parts • Tube and Reflector Components Figure 5.2 • Tube & Reflector Components 82 20C/20D e pip ail T ing ns e nd Co 106 26H 1516B/1516C/1516D 113 19B e (s ub T r tte mi E nt dia Ra 579 105 on sti u mb Co r (s be m a Ch 26B ) 21B 1215/1255 26A/26C ) 65I V55A/V56A/V57A 21B/220 1289 V301/V302/V303 V-24 1525 826 1527 832 V-D/V-D-SS 1528 V-23 1565 1566 Part No. Description Part No.
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 Detroit Radiant Products Company to the original user against defects in workmanship or materials under normal use for one year after date of purchase.
