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Form I-VR (Version F) Obsoletes Form I-VR (Version E) INSTALLATION / OPERATION / MAINTENANCE Model VR (std 60 Hz or optional 50 Hz) and Model GVR (std 50 Hz) Gas-Fired, Tubular, Radiant, Low-Intensity Infrared Heater ® Applies to: M TY P N Q UA E RO LITY SYST RA DU CT WA R STA RT-UP AG C T CQS C U S TO M E R Model VR Burner/Control Box with 20 - 70 ft Tube/Reflector Length S PROC CY E EN VERGE S N ON ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could r
Table of Contents 1. General..............................................2-3 1.1 Cautions and Warnings................. 2 1.2 Warranty ...................................... 3 1.3 Installation Codes......................... 3 2. Location ............................................3-5 3. Uncrating/Packaging........................5-6 7. Electrical and Wiring ...................31-32 7.1 Wiring Diagram .......................... 32 7.2 Control Thermostat..................... 32 8.
California Warning Label If the heater is being installed in the state of California, the installer MUST attach a warning label on the outside of the unit. The California Warning Label is shipped in the owner’s envelope along with this manual, the warranty form, and any other paperwork that applies. If installation is in California, select a location on the rear of the burner box. Be sure the surface is clean and dry and adhere the label.
2. Location (cont’d) Form I-VR, P/N 205202 R13, Page 4 trial installations only. Do not install these tubular radiant heaters in areas that contain corrosive or toxic fumes or where elements in the atmosphere could produce corrosive or toxic fumes in the presence of an open flame. These heaters do not qualify for explosion-proof installations. Clearance to combustibles must be observed (See Paragraph 5), including clearances to stock that might be periodically stacked underneath the heater.
Mounting Height Table 3. Uncrating/ Packaging should be located parallel to the wall. The distance from the wall is determined by whether the reflectors will be angled or horizontal. For spot heating applications, the tubular system should be located to direct the rays toward the area requiring heat. Depending on the installation, this can be done from directly overhead or reflector angled from the side. U-tube configurations are often best suited for overhead spot heating applications.
3. Uncrating/ Packaging (cont’d) Important NOTE: Before installation, wipe any excess corrosion inhibitor from the heat exchanger tubes. Failure to do so could result in excessive smoke from the surface of the tubes on first startup. (NOTE: Chain for hanging is not included. Use either an optional hanger kit (Option CK11) and/or a turnbuckle kit (Option CK12-18) or field-supplied hardware. See suspension requirements in Paragraph 5.
Size Configuration With “U” Or With 2 “L” Tube “L” Tubes Allowable Straight Lengths by Size and Configuration (feet) Straight Straight With 5-ft Tube With 5-ft Tube(s) & “U” Or “L” Tube 50 20, 30, 40 20, 30, 40 20, 30, 40 25, 35 25, 30, 35, 40 75 20, 30, 40 20, 30, 40 20, 30, 40 25, 35 25, 30, 35, 40 100 30, 40, 50 30, 40, 50 30, 40, 50 35, 45 30, 35, 40, 45, 50 125 30, 40, 50, 60 30, 40, 50, 60 30, 40, 50, 60 35, 45, 55 30, 35, 40, 45, 50, 55, 60 150 40, 50, 60 40, 50, 60 40
4. Dimensions, Configurations, and Clearances (cont’d) Required clearances depend on the size of the heater (BTUH input), the position of the reflector, and the addition of an optional side shield on the rear side of the heater. Refer to illustrations in FIGURE 3 to define clearances. The stated clearance to combustibles represents a surface temperature of 90°F (32°C) above room temperature. Building materials with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.
Straight System Length ft M 70 ft 21.3 60 ft 18.3 50 ft 15.2 40 ft 12.2 30 ft 9.1 20 ft 6.1 Expansion inches mm 2-3/4 70 2-3/8 60 2-1/8 54 1-7/8 48 1-1/2 38 1-1/8 29 Each straight tube section must have a suspension point. Straight sections adjacent downstream to a “U” or “L” tube require two suspension points. There must be a suspension point within 12 inches (305mm) of every coupler. Since the heater must be level, a turnbuckle is recommended at each suspension point.
6. Mechanical (cont’d) 6.1 Prepare the Burner/Control Box (cont’d) FIGURE 4 - Change the Combustion Air Restrictor Plate • 1st, remove and discard the factory Combustion Air Restrictor Plate installed restrictor plate. (Save the nuts.) • 2nd, attach the restrictor plate from the conversion parts bag. 3. Change Burner Orifice - Open both access panels on the bottom of the burner/control box. Locate the burner orifice (See FIGURE 5).
Additional Burner Box Preparation for Operation Above 6000 ft (1830M) FIGURE 7 High Altitude Pressure Switch is Required above 6000 ft (1830 M) Elevation on Sizes 50-175 If a Model VR/GVR 50-175 is being installed at an altitude above 6000 ft (1830M), the pressure switch will have to be changed. If ordered with the unit as Option DJ20, the pressure switch is shipped separately. (NOTE: Model VR200 does not require a pressure switch change above 6000 ft/1830M.
6. Mechanical (cont’d) 6.2.2 Suspend the Assembled Burner/Control Box and Combustion Chamber Tube (cont’d) 6.2 Assemble and Suspend the Heater (cont’d) NOTE: One “hook” of the wire retainer is bent 75° and the other 45°. If the reflector is going to be rotated, be sure the side with the 45° bend will be at the lower side. FIGURE 9 Wire Reflector Retainer, Hanger Bar, and Tube Bracket FIGURE 10 Bottom View with Wire Reflector Retainer and Tube Bracket Installed (Hanger bar is not illustrated.
FIGURE 12 Attaching Hanging Chain at Tube Suspension Points Chain attached to suspension point. “S” Hook Hanger Bar NOTE: Reflectors shown here will be installed after all chains are in place. 6.2.3 Install the Heat Exchanger Tubes and Turbulator Strip Sections Refer to illustrations in FIGURES as noted. Follow Steps in order.
6. Mechanical (cont’d) 6.2.3 Install the Heat Exchanger Tubes and Turbulator Strip Sections (cont’d) 6.2 Assemble and Suspend the Heater (cont’d) with nuts. (NOTE: Nuts must be secure before heater is operated, but if the reflector is going to be rotated, nuts may be installed loosely now and tightened later.) Hook the wire retainer out through the ends of the tube bracket. (NOTE: One “hook” of the wire retainer is bent 75° and the other 45°.
FIGURES 16A and 16B - Interlocking Turbulator Strip Sections Turbulator Requirements Length of Straight Tubes BTUH Size (000) Figure 16A - Turbulator Strip Sections Configuration (See Requirements in Paragraph 6; allowable layouts are illustrated in Form T-VR-CNFG.) Figure 16B - As turbulator strip is installed in the tube, interlock the sections. Turbulator Sections (Some sections may not be used; follow instructions.
6. Mechanical (cont’d) 6.2 Assemble and Suspend the Heater (cont’d) 6.2.3 Install the Heat Exchanger Tubes and Turbulator Strip Sections (cont’d) Turbulator Requirements (cont’d) FIGURE 17A - Examples of configurations with the exhaust heat exchanger tube adjacent to a straight heat exchanger. To install turbulator: 1) Insert a turbulator section into the exhaust heat exchanger tube.
NON-SLIP overlaps are required at each end of the “U” or “L” tube reflector. • No more than five consecutive NON-SLIP overlaps in a section containing two “L” tube reflectors. NOTE: Four of the five overlaps are required at each end of the “L” tube reflectors. • No consecutive SLIP overlaps. • Straight system MUST comply with the installation illustrated in FIGURE 19D for the length of system being installed. 3. Begin reflector installation at the combustion chamber end.
6. Mechanical (cont’d) Straight Tube Reflector Installation Instructions (cont’d) 6.2 Assemble and Suspend the Heater (cont’d) 6.2.4 Install Reflectors and Optional Side Shield and/or End Covers (cont’d) FIGURE 19D Reflector Overlaps (Straight Systems) 7. SLIP Overlap (One on 40 & 50 ft systems and two on 60 & 70 ft systems) Install reflector with a 1-1/2” (38mm) overlap. Do not screw the reflectors together.
Side Shield Installation Instructions FIGURE 20 - Drill 2 holes and cut a slot in each end of the first side shield section. Reflector End Covers, Option CD27 Because side shields can be installed anywhere along the tube length and use the same wire reflector retainers and tube brackets as the tubes, the side shield hanger slots must be made in the field to match the system. Therefore, the first hanger slot location is shown in FIGURE 20.
6. Mechanical (cont’d) 6.2.4 Install Reflectors and Optional Side Shield and/or End Covers (cont’d) 6.2 Assemble and Suspend the Heater (cont’d) • Reflectors on straight systems with a side shield may be angled 15° or 30°. The side shield must hang vertically. • Reflectors on “U” systems without a side shield may be angled 15°, 30° or 45° or 15° or 30° with a side shield. Follow option installation instructions. • If the system includes an “L” heat exchanger tube, the reflectors cannot be angled.
WARNING: This appliance is equipped for a maximum gas supply pressure of 1/2 pound, 8 ounces, or 14 inches water column. NOTE: Supply pressure higher than 1/2 pound requires installation of an additional service regulator external to the unit. PRESSURE TESTING SUPPLY PIPING Test Pressures Above 1/2 PSI: Disconnect the heater and manual valve from the gas supply line which is to be tested. Cap or plug the supply line. Test Pressures Below 1/2 PSI: Before testing, close the manual valve on the heater.
6. Mechanical (cont’d) 6.3 Gas Piping and Pressures (cont’d) Use a joint compound that is resistant to propane gas at all connections. Test all gas lines using a leak-detecting solution. FIGURE 23 - Gas Connection Installation Requirements THE GAS SUPPLY NIPPLE MUST BE PARALLEL TO THE HEATER MOVEMENT VERTICAL (AS SHOWN AT LEFT ) 3” (76mm) MAX. DISPLACEMENT ALTERNATE POSITIONS OKAY 12” (305 mm) CORRECT POSITIONS END VIEW HEATER MOVEMENT WARNING: CONNECTOR MUST BE INSTALLED IN “ ” CONFIGURATION.
But if adjustment is required, set pressure to correct settings by turning the regulator screw IN (clockwise) to increase pressure. Turn regulator screw OUT (counterclockwise) to decrease pressure. Remove manometer, replace the cap, and check for leak at pressure tap. CAUTION: DO NOT bottom out the gas valve regulator adjusting screw. This can result in unregulated manifold pressure causing excess overfire and heat exchanger failure.
6. Mechanical (cont’d) 6.3 Gas Piping and Pressures (cont’d) BTUH Inputs by Altitude and 14” w.c. for Sizes 175-200. For propane gas, the inlet pressure must be between 11” and 14” w.c. Take this reading as close as possible to the heater (Heaters are equipped with gas valves that have an inlet pressure tap.) If the inlet pressure is not within the specified range, the inlet pressure must be corrected and Steps 3 and 4 repeated. 6.
Vent Length Table surrounding ambient temperature is 60°F unless otherwise noted (See Vent Requirement No. 6, Condensation). Do not exceed maximum vent length. Minimum vent length is 5 feet (1.5M).
6. Mechanical (cont’d) 6.4 Venting and Combustion Air (cont’d) 6.4.1 Specific Venting Requirements (cont’d) FIGURE 25 - Attach Single-Wall Metal Vent Pipe to Exhaust Heat Exchanger Tube Use a compression coupling to attach a straight or elbow, single-wall vent pipe. Elbow must be attached so that the vent is horizontal or above. 1) Slide coupling (with bolts toward the bottom) over exhaust heat exchanger tube as far as it will go. 2) Slide elbow or straight pipe into coupling until it stops.
Products of combustion can cause discoloration of some building finishes and deterioration of masonry materials. Applying a clear silicone sealant that is normally used to protect concrete driveways can protect masonry materials. If discoloration is an esthetic problem, relocate the vent or install a vertical vent. Horizontal Vent Clearance Table Minimum Clearances for Vent Termination Location (all directions unless specified) Forced air inlet within 10 ft (3.1m) 3 ft (0.
6. Mechanical (cont’d) 6.4 Venting and Combustion Air (cont’d) 6.4.
Dual Vent Terminal Arrangements with Option CC5 Single-wall outer dual vent pipe Single-wall inner dual vent pipe FIGURE 28A Vertical Dual Vent Terminal Arrangement
6. Mechanical (cont’d) 6.4 Venting and Combustion Air (cont’d) 6.4.3 Unvented Installation (cont’d) DANGER: The fresh air requirement of 4 CFM per 1000 BTUH for natural gas and 5 CFM per 1000 BTUH for propane gas is mandatory when operating a heater in the unvented mode. See Hazard Levels, page 2. • Do not operate in the unvented mode if there is any doubt about the qual- ity of the insulation in the building.
1. Air from inside building -- openings 1 square inch free area per 1000 BTUH. Never less than 100 square inches free area for each opening. See (1) in FIGURE 30. 2. Air from outside through duct -- openings 1 square inch free area per 2000 BTUH. See (2) in FIGURE 30. 3. Air direct from outside -- openings 1 square inch free area per 4000 BTUH. See (3) in FIGURE 30. NOTE: For further details on supplying combustion air to confined space, see National Fuel Gas Code Z223.1 (latest edition).
7. Electrical and Wiring (cont’d) directly from the main electrical panel to the heater. All external wiring must be within approved flexible conduit and have a minimum temperature rise rating of 60°C. Conduit must not be run directly under the infrared tubes and should not interfere with the heater access panel. Allow slack in the flexible conduit to allow for heater expansion and contraction.
FIGURE 32 Thermostat Connections Terminal Strip on the Burner Box for Thermostat Connections of the infrared rays. See the wiring diagram in FIGURE 31 or inside the heater door panel. Unit-Mounted Thermostat Bracket, Option CM3 The optional thermostat bracket kit allows attachment of the controlling thermostat to the burner/control box. The bracket attaches at the same location as the thermostat strip and includes a junction box for mounting the thermostat.
8. Check Installation and Start-Up (cont’d) Start-Up: Bleed all air from the gas supply lines to the heater. Rotate the knob on the Check installation after start-up: With the unit operating, measure manifold gas pressure. See Paragraph 6.3. Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition. Place "Owner's Envelope" containing the Warranty Form and this manual in a safe, accessible location near the heater.
9. Maintenance 9.1 Maintenance Requirements As with any gas-burning equipment, regular maintenance procedures are required to ensure continued safety, reliability, and efficiency of the installation. If service is required, this heater should be serviced only by a qualified service person. Service information in this booklet is intended as a guideline for a qualified gas-fired equipment service person. Model VR and GVR tubular infrared heaters are designed to need only a minimum amount of maintenance.
9. Maintenance (cont’d) 9.2 Maintenance Procedures (cont’d) 9.2.4 Vent Pipe 9.2.5 Connection Couplings 9.2.6 Vent and/or Combustion Air Terminal 9.2.7 Combustion Air System CAUTION: Use of eye protection is recommended. S During a “cold” startup, transient condensation is formed. Over a period of time, condensation will cause metal pipe to develop holes and eventually fail completely. Replace any vent pipe that has condensation damage.
FIGURE 34 - Remove Combustion Air Restrictor Plate Combustion Air Restrictor Plate FIGURE 35 Clean the Blower Wheel Blower Wheel Clean the blower wheel using a brush, lowpressure compressed air, and an aerosol degreaser or refrigerant coil cleaner. Be careful not to damage the blower wheel. Replace the restrictor plate. 5) Clean the blower wheel. Remove any dust, dirt and/or oily deposits. Non-oily deposits can be removed with a small brush and low-pressure compressed air.
9. Maintenance (cont’d) 9.2 Maintenance Procedures (cont’d) 9.2.8 Main Burner (cont’d) FIGURE 36A - Open the Burner Compartment and Remove the Burner First, remove these two screws. Then, supporting the front of the burner, remove the brass nut at the other end. Remove burner. FIGURE 36B Burner Removed for Cleaning 9.2.9 Spark Electrode Assembly CAUTION: Due to high voltage on the spark wire and electrode, do not touch when energized. See Hazard Levels, page 2.
FIGURE 37A - Spark Electrode Assembly as seen through the front of the box (only visible when the combustion chamber is not attached.) Spark Electrode Assembly FIGURE 37C Spark Gap FIGURE 37B Remove Spark Electrode Assembly Remove the screw and carefully remove the spark electrode assembly. 10.1 Control Location, Operation, and Service 10. Service To service this heater, it is necessary to understand the normal operating functions of the heater controls.
10. Service (cont’d) 10.1 Control Location, Operation, and Service (cont’d) FIGURE 39 Pressure Switch Pressure Switch Function - The pressure switch is a safety control to ensure that adequate air is being provided for proper combustion. The device “senses” a small differential pressure created by the flow of the combustion air. Sensing Pressure Check (requires a Phillips screwdriver, a sensitive slope gauge, several feet of 3/16” O.D. rubber tubing, and two 1/4” O.D.
Ignition Controller FIGURE 40 Ignition Controller Function - The ignition controller functions to ignite the burner and as a flame supervision device. The ignition controller will shut off main burner gas flow immediately if the burner flame is lost. Burner ignition is achieved by a high voltage (18kV) spark that occurs across the spark electrode. The proper gap and location are important. CAUTION: Do not attempt to measure flame current signal.
10. Service (cont’d) 10.2 Troubleshooting WARNING: Service work on this heater should only be done by a qualified gas service person. All service information including the Troubleshooting Guides is intended as an aid to a qualified service person. Check the Light on the DSI Control Board LED Codes The DSI control board monitors the operation of the heater and includes a LED signal light that indicates normal operation and various abnormal conditions.
PROBLEM Burner cycles on and off PROBABLE CAUSE 1. Gas pressure too high or too low. REMEDY 1. See Gas Supply Pressure Table, Paragraph 6.3. 2. DSI control board not grounded. 3. Faulty DSI control board. 2. Make certain DSI control board is grounded to furnace chassis. 3. If 24 volt is available to the DSI control board and all other causes have been eliminated, replace board. 4. a) Make sure unit is properly vented. b) Remove obstructions from vent. c) Replace faulty tubing to pressure switch. 5.
10. Service (cont’d) FIGURE 45 Basic Troubleshooting Guide Is the gas supply turned on? YES 10.2 Troubleshooting (cont’d) Correct supply prssure by adjusting field-supplied pressure regulator or add a pressure regulator as appropriate. NO NO Open all manual gas valves in the supply line to the heater. Rotate the knob on the combination valve to the "ON" position. Is the gas supply pressure correct (Refer to Paragraph 6.3)? YES NO Turn on main electrical supply.
Addendum FIGURE 47 Attaching DoubleWall (Type B) Pipe to Single Wall Pipe Instructions for Attaching Double-Wall Vent Pipe (Type-B) FIGURE 47 - STEP 1 On the single-wall pipe, where illustrated, place a continual 1/4 inch bead of silicone sealant around the circumference. Do STEP 2 immediately following STEP 1. FIGURE 47 - STEP 2 Insert the single-wall pipe into the inner pipe of the double-wall pipe until the bead of sealant contacts the inner pipe creating a sealed joint.
Addendum (cont’d) Electrical Characteristics Model VR/GVR Technical Information Model VR (std 60 Hertz) Voltage/Phase Standard 115/1; Optional 208/1, 230/1 Frequency 60 hertz Control Amps (24V) 0.8 Main Burner Ignition Direct Spark Sizes 50, 75, Sizes 125 Full Load Amps Size 175 and 100 and 150 115V 1.1 0.8 1.2 Optional 208V or 230V 0.5 0.5 0.6 Maximum Overcurrent 15 15 15 Protection Size 200 1.
Index A Accessory Cartons 6 Addendum 45 Angle Reflectors 20 Assemble the Burner/Control Box and the Combustion Chamber Tube 11 B Blower Wheel 37 BTUH/Length/Configurations 46 Burner 37 Burner/Control Box 9 Burner/Control Box Packages 5 Burner Orifice 10 C California Warning Label 3 Chain 8 Check Installation 33 Clean the Burner 38 Clearance Orientation 8 Clearances to Combustibles 8 Combustion Air 30 Combustion Air Blower System 41 Combustion Air Inlet Kit 31 Combustion Air Pipe Length 31 Combustion Ai
INSTALLER MUST COMPLETE THE FOLLOWING: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Contact ________________________________
