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Gas-Fired Products 40 manual

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  • Page 1

    Form #43343530 July 08 INSTALLATION AND OPERATION INSTRUCTIONS OWNER / INSTALLER : For your safety this manual must be carefully and thoroughly read and understood before installing, op erating or servicing this heater. I NFRARED RADIANT TUBE HEATER Two Stage Push Through System (Positive Pressure) Models : PTS SERIES: (40, 50, 75, 100, 125, 150, 1[...]

  • Page 2

    Form #43343530 July 08 –1– T A B L E O F C O N T E N T S SECTION DESCRIPTION PAGE 1.0) Safety .................................................................................................................... .................... 2 2.0) Installer Responsibility ..................................................................................[...]

  • Page 3

    Form #43343530 –2– JJuly 08 1.0) SAFETY This heater is a self-contained two stage infrared radiant tu be heater. Safety information required during installation and operation of this heater is provided in this manual and t he labels on the product. The installation, service and maintenance of this heater must be performed by a contract or quali[...]

  • Page 4

    Form #43343530 July 08 –3–  (FOR CANADA ONLY) Every heater shall be located with respect to building constru ction and other equi pment so as t o per mit acces s t o the heater. Each installer shall use quality installation practic es wh en loc atin g the heate r and must give c onsi derat ion t o clearances to combustible ma terials, vehicl[...]

  • Page 5

    Form #43343530 –4– JJuly 08 4.0) MINIMUM CLEARANCES TO COMBUSTIBLES Failure to do so may result in death, serious injury or property damage. Combustible material must be located outside the clearance dimensions listed. Minimum clearances to combusti bles shall be measured from the outer surfac es as sh own in the f ollowing diagr am: MINIMUM CL[...]

  • Page 6

    Form #43343530 July 08 –5– 5.0) SPECIFICATIONS * MOUNT HEATERS AS HIGH AS POSSIBLE. Minimums are shown as a guideline for human comfort and uniform energy distribution for complete building heating applic ations. Consult your Space-Ray representative for the particulars of your installation requirements. Type Gas: Gas-Pipe Connection: Tube Diam[...]

  • Page 7

    Form #43343530 –6– JJuly 08 BURNER PACKAGE NUMBERS: NATURAL GAS PROPANE GAS MODEL NO PART NO . PTS/U 40-N7 #44149510 PTS/U 50-N7 #44149530 PTS/U 75-N7 #44149550 PTS/U 100-N7 #44149570 PTS/U 125-N7 #44149590 PTS/U 150-N7 #44149610 PTS/U 175-N7 #44149630 PTS/U 200-N7 #44149650 MODEL NO PART NO . PTS/U 40-L7 #44149520 PTS/U 50-L7 #44149540 PTS/U 7[...]

  • Page 8

    Form #43343530 July 08 –7– C) PTS 40-200 Series Body Package Descriptions – ALC Option (Aluminized Calorized) (Package Part Number is indi ca ted on the outside of carton.) S y s t e m L e n g t h s PTS Body Packages – Aluminized/Aluminized or Alumi-Therm/Aluminized 10 Ft. Pkg 44134020 20 Ft. Pkg 44135020 30 Ft. Pkg 44136020 40 Ft. Pkg 4413[...]

  • Page 9

    Form #43343530 –8– JJuly 08 Body Fastener Kit (included in body packages) 42907190 42907210 42907210 42907221 42873000 U-Bolt 2 4 4 6 02127110 Hex Nut, 5/16-18 5 8 8 13 02189020 HWHSM Screw, #10-16 x ½” TEKS 8 14 14 24 U-Bend Package 43208020 43208020 43208020 43208020 42873000 U-Bend 1 1 1 1 43318500 31” Tube Support/Hanger Bracket 1 1 1 [...]

  • Page 10

    Form #43343530 July 08 –9– Body Fastener Kit (included in body packages) 42907190 42907210 42907210 42907221 42873000 U-Bolt 2 4 4 6 02127110 Hex Nut, 5/16-18 5 8 8 13 02189020 HWHSM Screw, #10-16 x ½” TEKS 8 14 14 24 U-Bend Package 43208020 43208020 43208020 43208020 42873000 U-Bend 1 1 1 1 43318500 31” Tube Support/Hanger Bracket 1 1 1 1[...]

  • Page 11

    Form #43343530 –10– JJuly 08 C) Corner Reflector Acce ssory Package, Part #43342000 (Option for PTS Series Only) Contains : Corner Reflector Assembly, #43345000…… QTY–1 Speed Clips, #02266010…… QTY–4 D) U-Bend Package, Part #43208020 (Option for PTU Series Only) Contains : U-Bend, #42913020…… QTY–1 #10-16 x ½ Self-Drilling Sc[...]

  • Page 12

    Form #43343530 July 08 –11– 7.0) TYPICAL LAYOUTS – PTU / PTS Series Burner Box Flue T ermination 10 FT . Body Section 30 FT . SYSTEM 40 FT . SYSTEM 20 FT . SYSTEM 50 FT . SYSTEM 60 FT . SYSTEM 70 FT . SYSTEM 10FT . SYSTEM 5 FT . Body Section 90 Deg. Elbow 180 Deg. U-Bend LEGEND EMITTER LENGTH BODY LENGTH MODEL Min. Max. MODEL Min. Max. PTS 40[...]

  • Page 13

    Form #43343530 –12– JJuly 08 60 FT . SYSTEM 50 FT . SYSTEM 20 FT . SYSTEM 30 FT . SYSTEM 40 FT . SYSTEM LEGEND Burner Box 10ft Aluminized T ube 24 Hole Flange or 10ft Alumi-Therm Tube 6 Hole Flange Coupling 10f t Aluminized or HRS T ube model dependent 2ft Aluminized S teel T urbulator sections 70 FT . SYSTEM 10 FT . SYSTEM 2ft S t ainless S te[...]

  • Page 14

    Form #43343530 July 08 –13– 8.0) DIMENSIONS – PTS Series Typical Dimensions Up to 60 Ft. Shown. Burner Box 13 T ube Support/ Hanger Bracket Wire Hanger 4 T ube Coupling (typical) Bottom View Wire Hanger Wire Hanger 13 Tube Support/ Hanger Bracket 13 T ube Support/ Hanger Bracket 108 (274cm) 720 (1829cm) 108 (274cm) 108[...]

  • Page 15

    Form #43343530 –14– JJuly 08 8.1) DIMENSIONS – PTU Series Typical Dimensions Up to 50 Ft. Shown. Models: PTU 40, 50, 75 Models: PTU 50, 75, 100, 125 Models: PTU 100, 125, 150, 175 Models: PTU 125, 150, 175, 200 300 (762cm) 108 (274cm) 12 (30cm) 12 (30cm) Bottom View Wire Hangers (typical) 108 (274cm) 12 (30cm) 240 (610cm)[...]

  • Page 16

    Form #43343530 July 08 –15– 8.2) HEATER ASSEMBLY / JOINING OF TUBE SECTIONS T ypical Assembly Overview (PTS 40FT Shown) 4"OD x 10Ft. T ube See section 7 for required tubes. T ube Support Bracket U-Bolt Clamp & 5/16" Hex Nuts Mounting Flange 24 Hole for Aluminized S teel T ubes 6 Hole for Alumi-Therm S teel T ubes Wire Hanger Gaske[...]

  • Page 17

    Form #43343530 –16– JJuly 08 T ypical Assembly Overview (PTU 40FT Shown) Wire Hanger Flue T erminal #10 Self-Drill Screws (T ypical all tube supports, tube couplings and flue terminal.) 4"OD x 10Ft. T ube See section 7 for required tubes. 13 T ube Support Brk. with U-Bolt Clamp & 5/16" Hex Nuts Mounting Flange 24 Hole for Alumi[...]

  • Page 18

    Form #43343530 July 08 –17– 9.0) TYPICAL SUSPENSION METHODS Burner must be secured to the mounting flange with nuts. All materials used to suspend the heater must have a minimum working load of 1 15 lbs. All S Hooks must be crimped closed. Never use the heater to support a ladder or other access equipment. Failure to do so may result in d[...]

  • Page 19

    Form #43343530 –18– JJuly 08 10.0) ASSEMBLY OF TUBE SECTIONS Sheet metal part s, particularly reflectors and vent have sharp edges. Always use gloves when handling. Failure to do so may result in death, serious injury or property damage. CUT HAZARD During field assembly of the heater body sect ions, the recommended procedure is as follows: 1. B[...]

  • Page 20

    Form #43343530 July 08 –19– 10.1 ASSEMBLY OF EXTENSION SECTION See typical assembly overview (Section 8.0) for typi cal complete assembly. Assemble additional extension sections as required for all systems. (See Sectio ns 7.0, and 8.0 for typical layout details.) Join the tube sections together and secure with tube couplings as described below:[...]

  • Page 21

    Form #43343530 –20– JJuly 08 T ube Coupling Center both tubes with hole #10 Self-Drilling Screws (QTY 2) 4 5 7 6 4. Slide the next tu be into the coupling. 5. Make sure both tu be ends are butted together. 6. Finish tightening both bolts to 40-60 ft.lbs. torque to ensure a complete seal. 7. Use the two Self-drilling screws through the pre-punch[...]

  • Page 22

    Form #43343530 July 08 –21– MODEL 2 Ft. Turbulator Sections PTS/U 40/25 4 PTS/U 50/30 5 PTS/U 75/50 5 PTS/U 100/65 3 PTS/U 125/80 7 PTS/U 150/100 4 PTS/U 175/110 0 PTS/U 200/125 1 10.3) ADDING REFLECTORS 1. Slide the reflectors on the tube support/han ger brackets and through the wire hangers. 2. The tube at the coupling joints must be covered.[...]

  • Page 23

    Form #43343530 –22– JJuly 08 11.0) ADDING OPTIONAL 90º ELBOW (PTS ONLY) 1. The optional 90º elbow must be located a minimum of 10 ft. after the control box. 2 . H a n g t h e b o d y s e c t i o n s i n a 9 0 º ( " L " ) s h a p e d p a t t e r n . A llow spacing for the elbow. The distance from one end of the elbow to the centerli[...]

  • Page 24

    Form #43343530 July 08 –23– 11.2) ADDING 180°U-Bend (PTU ONLY) 1. Hang body sections parallel with each other. The center line distance from tube at each body section should be 18” as shown. 2. Join tube ends of body sections and the U-Bend together and secure with tube couplings as described in Section 10.1. 11.3) ADDING OPTIONAL U-BEND REF[...]

  • Page 25

    Form #43343530 –24– JJuly 08 12.0) ATTACHING BURNER BOX ASSEMBLY 1. Attach the burner box and gasket to end of tube flange and secure with 1/4-20 locknuts. 2. Assembl e the optional end reflector flush with the end of the main body reflector. Secure by sliding speed clips onto the reflector edges. Evenly space the speed clips on the sides (one [...]

  • Page 26

    Form #43343530 July 08 –25– S pool with TISS Wire Assembly 12.1) CONNECTING THE TISS SYSTEM Description: The TISS (Tube Integrity Safety System) i s d e s i g n e d t o s h u t t h e m a i n burner off in the event that a burnout occurs in the first 10ft. sectio n of firing tube. Note: When replacing the firing tube a new TISS wir e assembly PN[...]

  • Page 27

    Form #43343530 –26– JJuly 08 End View S pring Retainer Clamp S pring Thimble Wire & Sleeving Assembly TISS Wire Assembly PN 44176000 S pring Retainer Clamp 3. Mark the other end of the sleeve with tape or other marker . Use the top of the retainer as a reference. 4. Loosen screws. 2. T ape one end of the sleeve to the burner box or use a ma[...]

  • Page 28

    Form #43343530 July 08 –27– ANGLE MOUNTED HEATERS ONLY 5. If heaters are to be angle mounted, the TISS wire holder clamp must first be re-posit ioned as shown using the bottom hole pattern of the clamp. Follow procedures described earlier for all other adjustments. Step 5 Angle Mounted Body Section Re-position wire clamp using bottom hole patte[...]

  • Page 29

    Form #43343530 –28– JJuly 08 13.0) GAS CONNECTIONS AND REGULATIONS T ighten flexible gas hose and components securely . Flexible metal gas hoses must be installed without any twist s or kinks in them. The hose will move during operation of the heater and it can crack if it is twisted. Failure to do so may result in death, serious injury or prop[...]

  • Page 30

    Form #43343530 July 08 –29– * A vailable as Accessories KEY DIMENSIONS AND COMPONENTS OF THE GAS CONNECTIONS 14 to 17 (36 to 43cm) Approved Flexible Connector *Second S tage Regulator with V ent Leak Limiter to reduce the Supply Pressure below 14 W .C. Gas Pressure = 2 PSIG Gas Supply Piping Sediment T rap (Drip Leg) *Manual Gas Shut Off [...]

  • Page 31

    Form #43343530 –30– JJuly 08 14.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION SIDE VIEW 43269050 Rev. A 03/08 DANGER Failure to do so may result in death, serious injury or property damage FIRE HAZARD This access panel must be closed tightly with all the necessary screws during operation. Never operate the heater with the access panel open[...]

  • Page 32

    Form #43343530 July 08 –31– 15.0) ELECTRICAL CONNECTIONS Failure to do so may result in death or serious injury . This appliance must be connected to a properly grounded electrical source. Disconnect electrical power and gas supply before servicing. ELECTRIC SHOCK HAZARD 1. All electric wiring shall conform to the latest edition of the National[...]

  • Page 33

    Form #43343530 –32– JJuly 08 INTERNAL CONNECTION WIRING DIAGRAM — Direct Spark Ignition NOTES : 1. If any of the original wire as supplied with the applia nce must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC. (18 Ga. CSA 600V Type TEW) 2. When connecting the su pply circuit to the heate[...]

  • Page 34

    Form #43343530 July 08 –33– FIELD CONNECTION WIRING DIAGRAMS A. LOW VOLTAGE (24V) THERMOSTAT CONNECTIONS – SINGLE HEATER LO HI C Burner Control Box T wo-St age Thermost at (field supplied) Ground N Neutral L1 Hot (120V) Power Supply Cord (120V) Fused Disconnect Switch Continue T o Additional Heaters Receptacle High Fire Low Fire B. LOW VOLTAG[...]

  • Page 35

    Form #43343530 –34– JJuly 08 16.0) VENTING Failure to do so may result in death, serious injury , property damage or illness from Carbon Monoxide poisoning. Heaters installed in an unvented mode require a minimum ventilation flow of 4 CFM per 1,000 Btu/hr of total installed cap acity . In buildings with airborne contamination such as poultry ho[...]

  • Page 36

    Form #43343530 July 08 –35– the flue gases, the vent pipe should be insula ted and a condensation drain should be provided. 7. Minimum clearance for single-wall fl ue pipe to combustible material sha ll be 6 inches. This may be reduced when the combustible material is protected as specif ied in the National Fuel Gas Code or the authority having[...]

  • Page 37

    Form #43343530 –36– JJuly 08 MULTIPLE HEATER VENTING (CONNE CTIONS INTO A COMMON VENT OR MANIFOLD) Requirements for venting of multiple heaters are the same as de scri bed for SINGLE HEATER VENTING except as follows: 1. The common vent size and total vent height is norm ally determined by the number of heaters per common vent, length of horizon[...]

  • Page 38

    Form #43343530 July 08 –37– COMMON VENTING OF MULTIPLE HEATERS IN CONFINED SPACES IS PROHIBITED. If any heater connected to a common vent system for multiple heaters is found inoperative, the heater should be disconnected from the vent system and its entrance into the vent system capped. Multiple Heater Horizontal venting arrangement. 4 Diam[...]

  • Page 39

    Form #43343530 –38– JJuly 08 17.0) AIR FOR COMBUSTION If indoor combustion air is to be supplied for a tightl y en closed area, one square inch of free area opening shall be provided below the heater for each 1,000 Btu/hr of heater input. Adequate clearances around the air inlet screen m u s t b e m a i n t a i n e d a t a l l t i m e s . I n l[...]

  • Page 40

    Form #43343530 July 08 –39– In multiple heater app licat ions , the combustion air intake may be ducted individually or common ducted in the same configuration as shown for venting in Section 16.0. For combustion air intake duct sizing, please refer to the Vent Sizing Table and use the diameter indicated, based on the number of heaters per duct[...]

  • Page 41

    Form #43343530 –40– JJuly 08 19.0) SEQUENCE OF OPERATION The chart below shows the sequence of operation for the normal operating cycle of the PTS/PTU when connected to a permanent 120V power supply and th e heater is turned on and off by a remote 24V thermostat. (Electrical connection diagram B). T0 T1 T2 T3 T4 T5 T8 Call for heat, Thermostat [...]

  • Page 42

    Form #43343530 July 08 –41– 20.0) BURNER COMPONENT LOCATIONS Legend : 1 Cabinet Assembly 2 Access Panel - T op 3 Access Panel - Hinged (2 ea) 4 Access Panel - LH Burner 5 Access Panel - RH Burner 6 Air Inlet Screen 7 Gas Inlet Connection - 1/2NPT 8 Power Supply Cord - 120V 9 Burner Sight Glass 10 Indicator Light - Amber (Gas V alve) 1 1 Indi[...]

  • Page 43

    Form #43343530 –42– JJuly 08 21.0) CLEANING AND MAINTENANCE Failure to do so may result in death or serious injury . Disconnect electrical power and gas supply before servicing. ELECTRIC SHOCK & EXPLOSION HAZARD This heater must be cleaned and serviced annually by a qu alified contractor before the start of each heating season and at any ti[...]

  • Page 44

    Form #43343530 July 08 –43– 22.0) TROUBLESHOOTING GUIDE Turn on the gas valve? No Ye s Is the knob on the gas valve turned to the ON position? No Ye s Are the blue wires secure in the terminals and firmly on the ignition module terminals? Move orange wire to NO terminal. Restart troubleshooting. Replace motor . Remove any obstructions. Repeat s[...]

  • Page 45

    Form #43343530 –44– JJuly 08 Check external thermostat wiring and thermostat set point. No Ye s Remove red wire from the Low fire terminal, is there 24V at the center C terminal? No Ye s Is there 24V at the HI terminal on the gas valve? No Ye s With the thermostat set to low fire only does the low fire amber light come on after 15 seconds? No Y[...]

  • Page 46

    Form #43343530 July 08 –45– Purge the gas supply lines. Is the LED on the ignition module steady on? Replace ignition module. Remove and re-insert electrode. If it still sparks to the side. Replace electrode. No Ye s Check nameplate are the gas type, orifice and airplates correct for the stated burner specification? Carefully bend the terminal [...]

  • Page 47

    Form #43343530 –46– JJuly 08 23.0) REPLACING PARTS Failure to do so may result in death or serious injury . Disconnect electrical power and gas supply before servicing. ELECTRIC SHOCK & EXPLOSION HAZARD Only use genuine Space-Ray replacement parts. Parts are available from the factory for replacement by a licensed person. Refer to the Repla[...]

  • Page 48

    Form #43343530 July 08 –47– 23.2) REMOVAL OF GAS VALVE AND MANIFOLD ASSEMBLY S tep 1 Remove side access panel. Loosen screws from manifold clamp and burner assembly . S tep 3 Open hinged access panel and disconnect wires from gas valve. S tep 4 Remove (6) screws from end p anel. Rotate gas valve and manifold assembly slightly counter-clockwise [...]

  • Page 49

    Form #43343530 –48– JJuly 08 3. Connect plastic tubing of a digital or inclined water manometer with a 0-2” scale onto the connector tees. 4. Turn heater on and wait until blower motor is activated. 5. Observe air pressure from manometer. This should be higher than the set point indicated below for correct operation. Model Operating Pressure [...]

  • Page 50

    Form #43343530 July 08 –49– 24.0) INSTALLATION DATA Date of Installation: # of Heaters in System: Serial No. Model: PTS or PTU N = Natural Gas L = Propane Gas 25.0 REPLACEMENT PARTS GUIDE – BURNER BOX Item No. Part No. Description Qty. Fasteners 1 02295040 PHTCS #6-32 x 3/8" 3 1a 02266010 Speed Clips (for air inlet plate) 2 2 02261030 HH[...]

  • Page 51

    Form #43343530 –50– JJuly 08 29 42744079 Air Sensing Tube Asm. (straight) 1/4"od 1 30 42744069 Air Sensing Tube Asm. (90 deg bend) 1/4" 1 31 30635030 Cord Connector 1/2” #LPCG50 1 32 03988100 Plastic Vacuum Air Tube 10" (P2- to static pressure point) 1 33 03988100 Plastic Vacuum Air 10" (P1+ to total pressure point) 1 34 4[...]

  • Page 52

    Form #43343530 July 08 –51– 38a 22a 38 31 1 44 5 21 3 45 3 20 2 35 36 30 29 3 5, 5a 7 26 26a 25 24 1 22c 22b 14 1a 1a 22d 15 18 6 46 41, 41a 40 27 43 40a 3 17a 7 9a Draft Inducer Motor Gas Valve Air Switch Transformer Primary 120V Secondary 24V High Voltage Cable Electrode Gap 1/8 CONTINUE TO ADDITIONAL HEATERS Terminal Block CONNECTION WIRI[...]

  • Page 53

    Form #43343530 –52– JJuly 08 ALL ILLUSTRATIONS ARE INTENDED TO GIVE THE GENERAL IMPRESSION OF UNITS ONLY. O THER COMBINATIO NS OF 5 FT. AND 10 FT. SECTI ONS, AND ONES WITH OR WITHO UT THE ELBOW PACKAGE ARE POSSIBLE. PL EASE CONSULT WITH YO UR Space- Ray SALES REPRESENTATIVE. WE RESERVE THE RIGHT TO ALTER ANY SPECIFICATION WITHOUT NOTICE. BODY C[...]