Model Model SET - SETU & ITT - ITTU TWO STAGE 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.
SET / SETU and ITT / ITTU SERIES GAS FIRED INFRARED LOW INTENSITY TUBE TYPE TABLE OF CONTENTS TOPIC ........ PAGE TOPIC ……...PAGE 14. ELECTRICAL AND THERMOSTAT.................30 IMPORTANT INFORMATION - READ FIRST 15. HIGH ALTITUDE INSTALLATION ...................30 APPLICATION ............................................. 4 16. LIGHTING INSTRUCTIONS ...........................30 HEATER EXPANSION........................... 5, 31 17. RECOMMENDED MAINTENANCE .................30 GAS CONNECTION......
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 property damage, injury or death. Refer to Section 13 WARNING Gas Connection Improper installation, connection, or adjustment can result in property damage, toxic gases, asphyxiation, injury or death.
WARNING Tube “GLOW” It is a normal condition that the combustion tube (1st tube) can appear to “glow red”. For inputs up to 150,000 Btuh, the top surface of the tube can appear red where heat is trapped between the reflector and the tube. The stainless steel tube used for inputs 175,000 and greater can appear to entirely glow red. The tube material is designed into the heater because it can withstand the high temperature of combustion, and the “red glow” is a normal occurrence.
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.
tolerance which may degrade at lower temperatures are protected to prevent degradation. Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, etc. 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. Examples of low heat tolerance materials include vinyl siding, fabrics, some plastics, filmy materials, etc.
TABLE 2: GUIDELINES FOR HEATER PLACEMENT DISTANCE – OUTSIDE WALL TO HEATER LONG AXIS (PARALLEL TO WALL) IN “FEET” “Straight” or “U-Tube” MOUNTING HEIGHT ft (m) MAXIMUM DISTANCE BETWEEN HEATERS ft (m) SET / ITT 200/140 18 – 25 (6 - 8) 50 (15) 17 – 25 (5 - 8) SET / ITT 175/125 18 – 25 (6 - 8) 50 (15) 17 – 25 (5 - 8) SET / ITT 155/110 16 – 21 (5 - 7) 45 (14) 15 – 20 (5 - 7) SET / ITT 130/90 15 – 21 (5 - 7) 40 (12) 15 – 20 (5 - 7) SET / ITT 110/75 13 – 19 (4 - 6) 35 (11) 13 – 18 (4 - 6)
90° elbows (JS-0528-SM) are shipped as a kit with one coupler, and two reflector end caps. The SET / ITT is available in a “U-Tube” model - SETU / ITTU - 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 100/70 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 TURBULATOR NOTES: 1. 200,000 x 60 ft & 70 ft: REMOVE SHORT PIECE OF TURBULATOR FROM UPSTREAM END OF LAST TUBE PRIOR TO INSTALLATION OF TUBE 2. Turbulators are ALWAYS installed at the vent end of the heater. 9.
FIGURE 7: STRAIGHT TUBE TYPICAL HANGER & SUPPORT SPACINGS 6” MIN. to 24” MAX. SUSPEND ALL TUBES BY TWO (2) HANGERS PER 10’ LENGTH, LOCATE HANGERS BETWEEN 6” to 24” FROM EACH TUBE CONNECTION. 1ST & 2ND TUBES FROM BURNER END: INSTALL WELDED SEAM FACING DOWNWARD.
9.2 SETU / ITTU ‘U’-TUBE SYSTEM ~ BURNER AND TUBE INSTALLATION TURBULATOR NOTES: 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: 175,000 & 200,000 Btuh NOTE: The joint of 1ST & 2ND tubes of 175,000 & 200,000 heaters experience strong forces of expansion. Follow instructions below for special coupling of the tubes. SPECIAL COUPLER INSTALLATION 1. Note the 2 holes opposite each other at the swaged end of the first tube (flanged) 2. Install the first tube with 2 holes (swaged end) at the 3 and 9 o’clock position, with the welded seam located in the lower half of tube, facing downward 3.
10. REFLECTOR INSTALLATION NOTE: Ensure that you are installing a single reflector - reflectors can ‘stick together’ in packaging - take care to separate them. SET / ITT - 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. Install a minimum 36 inch (91 cm) length of minimum 26 gauge single walled 4” (10 cm) diameter vent pipe on the system, and a minimum 12 inch (30 cm) before any Tee or Elbow. 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 pipe. Any horizontal vent pipe must slope approx.
Use 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. 21).
VERTICAL VENT THROUGH THE ROOF: FIGURE 19 It is the sole responsibility of the installer to adhere to all current local codes and/or ANSI Z223.1 / CSA.B149.1 latest editions for all venting requirements, and practices. Approved Cap Use an approved ‘B-vent’ termination cap as supplied by the manufacturer of the approved ‘B-vent’.
12. COMBUSTION AIR DUCTING 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. This heater requires optional 4” Fresh Air Intake Adapter JS-0532-SE to connect an outside combustion air duct. An opening is located on the top surface of the burner housing for combustion air . Ensure adequate clearance around this opening 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, 52) 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.
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20. FENWAL DSI: SEQUENCE OF OPERATION / FLAME RECOVERY / SAFETY LOCKOUT Power Up / Stand By Upon applying 24 volts power to 24VAC, the control will reset, perform a self check routine, initiate full time flame sensing, flash the diagnostic LED for up to four seconds, and enter the thermostat scan state. Heat Mode When a call for heat is received from the thermostat supplying 24 volts to TH, the control checks the pressure switch for normally open contacts.
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 optional post purge period. Fault Conditions Error Mode The LED will flash on for 1/4 sec- Internal Control Failure ond, then off for 1/4 second during Air Flow Fault a fault condition.
SPARK IGNITER ADJUSTMENT Use the following diagram to check the Igniter gap. If the gap is incorrect all adjustments should be made to the GROUND PRONG/PIN ONLY! DO NOT BEND THE IGNITER PRONG!!!! USE THE BLACK BARS BELOW AS A GUIDE FOR ADJUSTMENT. USE THE BARS THAT COINCIDE WITH THE FORMAT & SIZE OF THIS PUBLICATION . IF this manual is in 8.5” x 11” “booklet” format (pages folded in half) 3/16” 1/4” then use these bars OR IF this manual is printed 8.
21. TROUBLESHOOTING GUIDE - FENWAL DSI (also see Heater Troubleshooting next page) SYMPTOM RECOMMENDED ACTION(S) 1. Dead A. B. C. D. 2. Thermostat on - no blower output A. Miswired B. Bad thermostat no voltage @ terminal W C. Bad control (check LED for steady on) Miswired - check electrical supply (120Vac ± 5%) Transformer bad (24Vac ± 10%) Fuse/Circuit breaker bad Bad control (check LED for steady on) A. Miswired (check PSW terminal voltage: 24Vac ± 10%) 3. Pressure switch input okay, B.
22. TROUBLESHOOTING GUIDE - HEATER OPERATION WARNING Improper adjustment, alteration, service or maintenance can cause property damage, injury or death.
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.
23. 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 20’ 30’ 40’ Tube ‘L’ = center air intake to vent end Length 20’-11 3/4” ; 251 3/4” ; 628 cm 50’ 30’-7 3/4” ; 367 3/4” ; 934 cm 60’ 40’-3 3/4” ; 483 3/4” ; 12
25A. BURNER & TUBE KIT ASSEMBLY CHART MODELS SET / ITT MODELS SET & ITT 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).
25B. 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).
26. 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 2-Stage Low Voltage Digital Thermostat (24 Volts - °F or °C selectable) Not for use in corrosive or wet environments JS-0569-DT Required For MULTIPLE HEATERS per Thermostat: 24 RELAY Multiple Tube Heaters controlled by a single 2-Stage Thermostat (field installed) SET(U)-F / ITT(U)-F Manual IM091221 RD: FEB 2014 RL: 8B JS-0568-XX 48
90 degree Aluminized Steel Elbow Kit (Kit includes: aluminized steel elbow, coupler, and two reflector end caps) JS-0508-SM For 180° elbow use two x JS-0508-SM, or use Model SETU / ITTU that includes 180° Turn Box Side Reflector Extension Kitl0” deep, l0 ft long Each Includes 3 ‘S’ Hooks JS-0509-KT Tube Protection Screen -5 foot lengths JA-0780-XX 49 SET(U)-F / ITT(U)-F Manual IM091221 RD: FEB 2014 RL: 8B
29. REPLACEMENT PARTS SET / ITT Burner # PART DESCRIPTION PART # PART DESCRIPTION PRIMARY 1 BURNER HOUSING JS-0582-XX Burner housing (painted orange) 2 PRESSURE SWITCH TUBING JS-0572-SE P.V.C. tubing set (2 x 20") 3 BURNER HEAD 4 5 6 AIR RESTRICTOR RING MAIN BURNER ORIFICE OUTER BURNER JS-0510-LP Burner head (45-80) JS-0512-XX Burner head (110-200) JS-0596-XX Burner head air rest. ring .375 60LP,60-200NG JS-0597-XX Burner head air rest. ring .
# 9 PART DESCRIPTION PART # AIR INLET C/W SCREEN PART DESCRIPTION PRIMARY SUPPLEMENT JS-0595-AC blower ring c/w 1 1/2" bird screen JS-0595-EP blower ring c/w 1 3/4" bird screen JS-0595-AE blower ring c/w 2" bird screen JS-0595-AB blower ring c/w 2 1/8" bird screen 130/90 LP JS-0595-EA blower ring c/w 3 1/8" bird screen 200/140 NG 80/60, 110/80 155/110 NG/LP, 130/90 NG 175/200 NG 10 BLOWER JS-0579-AA Blower assembly tube burner 11 MANIFOLD BUSHING JS-0589-XX Manifold bushing 12 90
SET / ITT & SETU / ITTU 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 TU
HONEYWELL S87J WIRING DIAGRAM - 24 VAC 2-STAGE THERMOSTAT (FENWAL DSI - PAGE 31; MULTIPLE HEATERS PER THERMOSTAT - PAGE 32) (CHANNEL MICRO 50N DSI - PAGES 56-58) Maximum Power Flow = 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.
HONEYWELL S87J 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.
HONEYWELL S87J 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.
CHANNEL MICRO 50N: WIRING DIAGRAM: 2-STAGE THERMOSTAT CONTROL OTHER DSI’s: FENWAL SEE PAGE 31; HONEYWELL S87J - PAGES 53- 55 The heater must be electrically grounded in accordance with the National Electrical Code. ANSI / NFPA 70 or current Canadian Electrical code CSA C22.1.
CHANNEL MICRO 50N DSI: SEQUENCE OF OPERATION The MICRO 50N is a three trial ignition control module with a 30 minute soft lockout/reset. It is powered through a safety control circuit by a 24v transformer that is activated when the thermostat calls for heat. On every call for heat the MICRO 50N will delay start-up with a 30 second system pre-purge. After pre-purge an electronic generator powers the spark igniter and retrial/ safety lockout timing begins.
CHANNEL MICRO 50N IGNITION CONTROL - SPECS The MICRO 50N is a microprocessor-based DSI (Direct Spark Ignition) control which continuously monitors the entire system to ensure safe operation under all conditions. Features of the MICRO 50N DSI Control include 30 second purge and 20 second ignition trial, with three ignition attempts, a diagnostic alarm output, automatic recycle on lockout (soft lockout).
LIMITED WARRANTY CERTIFICATE FOR GAS-FIRED INFRA-RED LOW INTENSITY TUBE HEATERS: SET / SETU & ITT / ITTU 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.