Model Model S100 - S100U & ITB - ITBU LOW INTENSITY TUBE TYPE INFRARED HEATERS INSTALLATION / OWNER’S MANUAL WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation and operating and maintenance instructions thoroughly before installing or servicing this equipment. SAFETY ALERT: This heater must be installed and serviced only by a trained gas service technician.
NOTICE: This manual is current for this product. Occasional revision of the product Certification Standard may require changes to the product and/or this manual. This publication, or parts thereof, may not be reproduced in any form, without prior written consent from The Manufacturer. Unauthorized use or distribution of this publication is strictly prohibited.
S100 - S100U and ITB - ITBU SERIES GAS FIRED INFRARED LOW INTENSITY TUBE TYPE TABLE OF CONTENTS TOPIC ........ PAGE TOPIC ……...PAGE 13. GAS SUPPLY ................................................. 27 INSTALLATION HEATER EXPANSION .................................... 28 IMPORTANT INFORMATION - READ FIRST FLEXIBLE GAS CONNECTION ...................... 28 APPLICATION ............................................. 4 14. ELECTRICAL AND THERMOSTAT ................ 30 HEATER EXPANSION ...................
WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read and understand this installation and operation manual thoroughly prior to assembly, installation, operation or service to this appliance. This heater must be installed and serviced only by a trained gas service technician. Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other gas fired appliance.
WARNING Heater Expansion It is a normal condition that during heat-up and cool-down a tube heater will expand and contract. Allowances for heater expansion must be made in the gas connection, venting and combustion air ducting. Improper installation, alteration, or adjustment can result in WARNING Gas Connection Improper installation, connection, or adjustment can result in property damage, toxic gases, asphyxiation, injury or death.
WARNING Clearance to combustibles Location of flammable or explosive objects, liquids or vapors close to the heater may cause fire or explosion and result in property damage, injury or death. Do not use, store or locate flammable or explosive objects, liquids or vapors in proximity of the heater. The clearance to combustible material represents the minimum distance that must be maintained between the outer heater surface and a nearby surface.
FIGURE 1 MINIMUM CLEARANCES TO COMBUSTIBLES* - refer to Table 1 for values NOTE: A ‘PEEL & STICK’ SIGN IS SUPPLIED: USE AN INDELIBLE MARKER TO ENTER VALUES ‘H’, ‘S’, ‘F’, & ‘B’ ON . POST THE SIGN ADJACENT TO THE HEATER THERMOSTAT OR IN A PROMINENT LOCATION. See next page for details.
It is the installer’s responsibility to ensure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation. VENT END CLEARANCE: Clearances from the vent pipe are determined by local or national installation codes, but must not be less than 6 inches (15 cm). For ‘unvented’ installation, a minimum distance of 24 inches (61 cm) is required from the end of heater to a combustible surface.
1. LABOR REQUIRMENTS Two persons are required to safely install this equipment. Wear gloves and other required safety protection. 2. INSTALLATION IN COMMERCIAL AIRCRAFT HANGARS Low intensity radiant tube heaters are suitable for use in aircraft hangars when installed in accordance with the latest edition of the Standard for Aircraft Hangars, ANSI/NFPA No 409 in the USA, or the Canadian Natural Gas and Propane Installation Code, B149.1. A.
WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read and understand this installation and operation manual thoroughly prior to assembly, installation, operation or service to this appliance. This heater must be installed and serviced only by a trained gas service technician. Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other gas fired appliance.
6. MOUNTING CLEARANCES This heater must be mounted with at least the minimum clearances between the heater and combustibles as shown in FIG-1, TABLE 1, Page 7. It is the installer’s responsibility to ensure that building materials with a low heat tolerance which may degrade at lower temperatures are protected to prevent degradation.
TABLE 2: GUIDELINES FOR HEATER PLACEMENT DISTANCE – OUTSIDE WALL TO HEATER LONG AXIS (PARALLEL TO WALL) IN “FEET” MOUNTING HEIGHT ft (m) MAXIMUM DISTANCE BETWEEN HEATERS ft (m) S100 / ITB 200 18 – 25 (6 - 8) 50 (15) 17 – 25 (5 - 8) S100 / ITB 175 18 – 25 (6 - 8) 50 (15) 17 – 25 (5 - 8) S100 / ITB 155 16 – 21 (5 - 7) 45 (14) 15 – 20 (5 - 7) S100 / ITB 130 15 – 21 (5 - 7) 40 (12) 15 – 20 (5 - 7) S100 / ITB 110 13 – 19 (4 - 6) 35 (11) 13 – 18 (4 - 6) S100 / ITB 100 13 – 19 (4 - 6) 35 (
90° elbows (JS-0528-SM) are shipped as a kit with one coupler, and two reflector end caps. The S100 / ITB is available in a “U-Tube” model - S100U / ITBU - using a 180° turn box. A double wide reflector covers the double tube run. Alternately, for a 180° elbow, order 2 x 90° kits that connect to create a 180°. IMPORTANT: Models with input 100 Mbh x 20 ft (30 kW x 6 m) must only be installed as a straight system with no elbows allowed at the 10 ft (3 m) location.
8. SUSPENDING THE SYSTEM - GENERAL Inadequate or improper suspension of the tube heater can result in collapse of the system, property damage, and personal injury or death. It is the installer’s responsibility to ensure that the hardware and structural supports from which the heater is suspended are sound and of adequate strength to support the weight and expansion forces of the heater. Consider that the heater will expand in length as much as 1/2 inch (12.
9 INSTALLATION OF HANGERS, TUBES AND BURNER 9.1 S100 / ITB STRAIGHT TUBE SYSTEM ~ BURNER AND TUBE INSTALLATION Note: Turbulators are ALWAYS installed at the vent end of the heater .
FIGURE 8 BOLTING BURNER TO FLANGED TUBE FIGURE 9 COUPLER 1 Eye Bolt 2 Fifth Nut (Holds Inner Burner to Housing Do Not Remove or Loosen) 3 Lock Washers (4) Four 4 Nuts (4) Four Note: Nuts may be shipped c/w lock-washers as one piece Insert four burner bolts through the tube flange, secure tightly with lock washers and nuts.
9.2 S100U / ITBU ‘U’-TUBE SYSTEM ~ BURNER AND TUBE INSTALLATION Note: Turbulators are ALWAYS installed at the vent end of the heater .
FIGURE 11 ‘U’-TUBE TYPICAL HANGER & SUPPORT SPACING SUSPEND FIRST TUBES BY TWO (2) HANGERS, THEN SUBSEQUENT SECTIONS BY ONE HANGER LOCATE HANGERTS BETWEEN 6” to 18” FROM EACH TUBE COUPLER. INSTALL FIRST AND SECOND TUBES (FROM BURNER END) WITH WELDED SEAM FACING DOWNWARD.
9.3 SPECIAL COUPLING: 100,000 Btuh x 20 ft and 175,000 & 200,000 Btuh For all other firing rates refer to Sections 9.1 (Straight Tubes) or 9.2 (‘U’-Tubes) NOTE: The joint between tubes of the 100,000, 175,000 & 200,000 heaters experience strong forces of expansion. Follow instructions below for Special Coupling of the tubes. TOOLS REQUIRED ¼” Drill Bit (supplied) Electric Drill COUPLER INSTALLATION - Perform prior to reflector installation - See Figure 14 below 1.
10. REFLECTOR INSTALLATION NOTE: Ensure that you are installing a single reflector - reflectors can ‘stick together’ in packaging - take care to separate them. S100 / ITB - STRAIGHT TUBE: After burner and tubes have been installed, slide the reflectors one at a time into the wire hangers. As each successive reflector is installed on an inline installation, the ends of the reflectors will overlap to provide continuous coverage over the entire tube system.
FIGURE 15 REFLECTOR EXTENSIONS (OPTIONAL - IF REQUIRED ) Reflector Extension Kit JS-0509-KT Includes: Qty 1 x 10 ft long x 10 inch deep reflector extension Qty 3 x “S” Hooks Reflector extensions may be installed one or both sides 10” 25 cm 1. Reflector extensions may be installed on one side or both sides of the reflector 2. Reflector extensions are 116” (295 cm) long 3. Holes (3) in the reflector extension for “S” hooks are located 2.25” (5.7 cm) from each end and one at the center 4.
WARNING 11. FLUE VENTING Inadequate venting of a heater may result in asphyxiation, carbon monoxide poisoning, injury or death. This heater may use a vent connection or indirect venting system to remove products of combustion from the space. Seal all vent connections with high temperature sealant. Venting must be in accordance with all local, state, provincial, and national codes (ANSI Z223.1/NFPA 54 in USA; B149.1 in Canada) and as indicated below in this manual.
heaters must be controlled by a single common thermostat or “ON/OFF” switch. A minimum 10 inch (25 cm) length of minimum 26 gauge single walled 4” (10 cm) diameter vent pipe is to be installed on the swaged end of the last tube before any Tee or Elbow is fitted. Seal all vent connections with high temperature sealant. Vent connections must be secured with three (3) #8 sheet metal screws uniformly spaced around the circumference of the vent pipe.
Use the approved 4" (10 cm) (JA-0528-XX) or 6" (15 cm) (JA-0529-XX) horizontal wall vent terminal or a high-wind termination cap approved by a recognized certification agency Install termination cap a minimum of 18 inches (45 cm) from the outside wall to the inside edge of terminal opening to alleviate back pressure caused by turbulent wind conditions (See Fig. 17).
VERTICAL VENT THROUGH THE ROOF: FIGURE 19 It is the sole responsibility of the installer to ad- Approved here to all current local codes and/or ANSI Cap Z223.1 / CSA.B149.1 latest editions for all venting requirements, and practices. Approved Use an approved ‘B-vent’ termination cap ‘B’ Vent as supplied by the manufacturer of the approved ‘B-vent’.
The air intake will not be located less than: Three feet above grade Twelve inches from flue vent terminal of any heater with input up to 100,000 Btu/hr. Three feet from flue vent terminal of any heater over 100,000 Btu/hr. Do not install filters on the combustion air intake. Ensure adequate clearance around the air intake to allow sufficient combustion air supply to the heater.
13. GAS SUPPLY - HEATER EXPANSION - FLEXIBLE GAS CONNECTION The gas supply must be installed to the heater using: USA: an approved Stainless Steel Flexible Gas Connector certified for use on an infrared radiant tube heater (ANSI Z21.24 CSA 6.10); CANADA: an approved Type 1 Hose Gas Connector (CAN/CGA 8.1). The heater must be isolated from the gas supply piping system by closing its individual manual shut off valve (field supplied) during any pressure testing of the gas supply piping system.
NOTE: Access to the manifold pressure test port is on the top of the valve. A 3/16" Allen Wrench is necessary to check this. When checking or setting the manifold pressure, a water manometer should be used. Gauges which measure in ounces per square inch or pounds per square inch are not accurate enough to properly measure or set the pressure. WARNING THIS HEATER WILL EXPAND IN LENGTH AS IT HEATS UP. It is a normal condition that during heat-up and cool-down a tube heater will expand and contract.
FIGURE 20 ORIENTATION OF FLEXIBLE GAS CONNECTOR The flexible gas connector MUST be installed in the orientation shown below as required by national installation codes and by the certification standard of this heater. This orientation protects the flexible gas connector from damage due to movement during heater expansion. It is the responsibility of the installer to ensure correct installation of the flexible gas supply.
14. ELECTRICAL AND THERMOSTAT WIRING (WIRING DIAGRAMS PAGE 35 & 36) NOTICE The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1. Appliance and control wiring must be in accordance with all applicable local codes. The total load of all heaters must be considered in determining the required contact rating of the controlling thermostat or switch.
18A. WIRING DIAGRAM: 120 VOLT THERMOSTAT OPERATION (24V Thermostat—next page) Maximum Power Flow = 21VA Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. The heater includes a 24V/120V relay switch . Maximum power flow for internal 24V burner components is 21VA. The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.
18B. WIRING DIAGRAM: 24 VOLT THERMOSTAT OPERATION (120V Thermostat - previous page) Field installed option Kit JS-0568-KT RELAY Maximum Power Flow = 21VA Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. The heater includes a 24V/120V relay switch . Maximum power flow for internal 24V burner components is 21VA. The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.
19. MULTIPLE TUBE HEATERS per THERMOSTAT OR Line Voltage Thermostat Each tube heater requires 120V, 60 HZ electrical power sized for 145VA. Maximum power flow for internal 24V burner components is 21VA. See previous pages for internal wiring. The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1. A maximum night set-back of 9°F (5°C) is recommended for optimum economy and comfort.
20 SEQUENCE OF OPERATION The S87 ignition control module is powered by a 24v transformer and activated when the thermostat calls for heat. On every call for heat the S87J will delay start-up to provide a 30 second system pre-purge. When the S87 is activated by a thermostat or call for heat an internal transformer provides power to the electronic generator circuit for Spark Ignition and the safety lockout timing begins.
21. TROUBLESHOOTING GUIDE WARNING Improper adjustment, alteration, service or maintenance can cause property damage, injury or death. This heater must be installed and serviced only by a trained gas service technician SEQUENCE OF EVENTS APPLY 120 VOLTS SET THERMOSTAT TO CALL FOR HEAT COMBUSTION AIR BLOWER STARTS CHECK IF 120 VOLTS PRESENT AT BLOWER IF “YES”.....
MAIN BURNER LIGHTS NO CHECK FOR STRONG SPARK AT IGNITER........ (SEE PREVIOUS PAGE). YES CHECK FOR 24 VAC ACROSS GAS VALVE. CHECK OUTPUT VOLTAGE FROM CONTROL TERMINALS TO GAS VALVE.....IF NO VOLTAGE REPLACE CONTROL. CHECK ELECTRICAL WIRING, AND VOLTAGE BETWEEN IGNITION CONTROL AND GAS VALVE. IF OK, REPLACE GAS VALVE.
22. SPARK IGNITION CIRCUIT The step-up transformer in the ignition control provides spark ignition at 30,000 volts (open circuit). To check the spark ignition circuit, proceed as follows.
23. FLAME SENSING CIRCUIT The output of the flame sensing circuit cannot be checked directly on the S87 body. Check the flame sensing circuit directly by checking the flame sensing current from the sensor to the S87 as follows. 1. Connect a meter (dc microammeter scale) in series with the flame signal ground wire as shown below. Using the Honeywell W136A Test Meter or equivalent. Disconnect the ground wire from the S87. Connect the red (positive) meter lead to the free end of the ground wire.
24. START-UP / COMMISSIONING SHEET THIS EQUIPMENT HAS BEEN FACTORY FIRED AND TESTED PRIOR TO SHIPMENT. HOWEVER, THIS APPLIANCE IS NOT “PLUG & PLAY”. IT REQUIRES COMMISSIONING AND FIELD ADJUSTMENT / SPECIFICATIONS CONFIRMATION TO ENSURE SAFE AND EFFICIENT OPERATION. COMMISSIONING REPORT AS PER I&O MANUAL AND LOCAL CODES CONTRACTOR NAME: ................................................................................DATE................................ ADDRESS:...............................................
QUALIFIED INSTALLER TO COMPLETE THIS TUBE HEATER COMMISSIONING REPORT TYPE OF GAS: NG LP DOES BUILDING HAVE A NEGATIVE CONDITION: YES NO IF THIS IS A HIGH ALTITUDE AREA WHAT IS THE ALTITUDE ABOVE SEA LEVEL Feet DOES APPLICATION REQUIRE FRESH AIR TO BURNER YES NO IS HEATER EXPOSED TO CHEMICAL OR CORROSIVE ATMOSPHERE: YES NO ARE ACTUAL MINIMUM CLEARANCES AS PER TABLE 3 YES NO CAN HEATER BE AFFECTED BY OVERHEAD CRANES / VIBRATION YES NO ARE GAS SUPPLY LINES ADEQUATELY SIZED FOR SYSTEM YES
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FIGURE 21 BURNER DIMENSIONS FIGURE 22 HANGER SPACING / LENGTH - AIR INTAKE TO VENT END POSITION BURNER END HANGER 4 INCHES (10 CM) FROM BURNER LOCATE SYSTEM HANGERS NO LESS THAN 6 INCHES (15 CM) AND NO MORE THAN 24 INCHES (61 CM) FROM TUBE COUPLING * ANGLE BURNER SUPPORT CHAIN BACK OVER BURNER - ALLOWS TUBE SYSTEM EXPANSION Tube Length 10’ 20’ 30’ 40’ Tube Length 50’ 60’ 70’ ‘L’ = center air intake to end 11’-3 3/4” ; 135 3/4” ; 345 cm 20’-11 3/4” ; 251 3/4” ; 628 cm 30’-7 3/4” ; 367 3/4” ; 9
26A. BURNER & TUBE KIT ASSEMBLY CHART MODELS S100 / ITB MODELS S100 & ITB are approved for indoor commercial / industrial non-residential applications. For outdoor, wet and harsh environment applications refer to models SPW-JZ / IWP (powder coated burner box) and/or STW-JZ / IW (stainless steel burner box).
26B. BURNER & TUBE KIT ASSEMBLY CHART MODELS S100U / ITBU MODELS S100U & ITBU are approved for indoor commercial / industrial non-residential applications. For outdoor, wet and harsh environment applications refer to models SPW-JZ / IWP (powder coated burner box) and/or STW-JZ / IW (stainless steel burner box).
27. TURBULATORS: NOTE: Improper location of a turbulator can cause malfunction of the heater, property damage, and will void the heater warranty. Tube Heaters are supplied with all required turbulator(s) factory installed into the tube(s). Tubes with turbulators are installed at the vent end of the system configuration and are clearly labeled for easy identification.
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Fresh Air Intake Adapter JS-0532-SE Fresh Air Intake Cap—Wall JS-0532-VC Fresh Air Intake Cap—Roof 4” roof cap JA-0530-XX 6” roof cap JA-0531-XX S100/ITB I&O Manual IM090513 RD: MAY 2009 RL: 4A- BA 48
Low Voltage Digital Thermostat (24 Volts - °F or °C selectable) Not for use in corrosive or wet environments JS-0569-WR TruTemp Thermostat True comfort control for radiant heating systems - senses and averages ambient and radiant temperatures. Occupancy sensor with auto set-back of 9°F (5°C).
JS-0508-SM 90 degree Aluminized Steel Elbow Kit (Kit includes: aluminized steel elbow, coupler, and two end plate hangers) For 180° elbow use two x JS-0508-SM, or use Model S100U / ITBU Side Reflector Extension Kitl0” deep, l0 ft long Each Tube Protection Screen -5 foot lengths S100/ITB I&O Manual IM090513 RD: MAY 2009 RL: 4A- BA JS-0509-KT JA-0780-XS For Builder Model 50
30 REPLACEMENT PARTS Optional Items 22 7 S100 / ITB Burner # PART DESCRIPTION 1 BURNER HOUSING 2 PRESSURE SWITCH TUBING 3 BURNER HEAD 4 AIR RESTRICTOR RING 5 MAIN BURNER ORIFICE PART # JS-0582-XX JJ-0582-XX JS-0572-SE JS-0510-LP-45 JS-0510-LP JS-0512-XX JS-0596-AA JS-0596-XX JS-0597-XX JS-0748-DM JS-0730-DM JS-0742-DM JS-0725-DM JS-0736-DM JS-0718-DM JS-0731-DM JS-0752-MM JS-0729-DM JS-0758-MM JS-0714-IN JS-0725-IN JS-0721-DM JS-0767-MM JS-0719-DM JS-0730-IN PART DESCRIPTION PRIMARY Burner housing
# PART DESCRIPTION 6 OUTER BURNER 7 EQUALIZER PLATE 7A BURNER AIR RESTRICTOR 8 BLOWER GASKET 9 AIR INLET C/W SCREEN 10 11 12 13 BLOWER MANIFOLD BUSHING 90 DEGREE ELBOW FITTING 1/2" GAS VALVE 14 15 16 17 18 4" NIPPLE TERMINAL BLOCK STEP DOWN TRANSFORMER COMPONENT PLATE COMBUSTION AIR PROVING SWITCH 19 BLOCKED FLUE PROVING SWITCH 20 IGNITION CONTROL Replacement Kit 21 IGNITION CABLE 22 EYE BOLT COMBUSTION AIR INTAKE ADAPTER 4" COMBUSTION AIR INLET WALL CAP 4" NOT SHOWN: ROOF CAP 4" HORIZONTAL FLUE VEN
S100 / ITB & S100U / ITBU TUBE SYSTEM PARTS # 24 25 26 27 PART DESCRIPTION WIRE HANGER REFLECTOR END CAP LOW INTENSITY TUBE PART # JS-0505-EH JS-0502-EM JS-0502-ES JS-0501-SW-P PART DESCRIPTION PRIMARY Small wire hanger Reflector (18" x 120") S100 / ITB series reflector end cap Aluminized tube,flanged,swaged c/w ports JS-0501-SK Aluminized tube, 10' slotted + Accuseal clamp JS-0499-SW-P Alumatherm tube,flanged,swaged c/w ports JS-0515-SW-P Steel tube 10' swaged 28 SIGHT GLASS ASSEMBLY 29 IGNITER KIT 30
LIMITED WARRANTY CERTIFICATE FOR GAS-FIRED INFRA-RED LOW INTENSITY TUBE HEATERS: S100 / S100U & ITB / ITBU SERIES The Manufacturer warrants that this product is free from defects in material or workmanship under normal use and service subject to the terms of this document.
