TUBE HEATERTROUBLESHOOTING GUIDE

MODELS: HLV Series Tube Heaterer

Detroit Radiant Products Company21400 Hoover Road • Warren • Michigan • 48089 • (586) 756-0950 • Fax: (586) 756-2626

website: www.reverberray.com email: engineering@detroitradiant.com

THESE HEATERS MUST BE INSTALLED AND SERVICED BY TRAINED GAS INSTALLATIONAND SERVICE PERSONNEL ONLY. READ AND UNDERSTAND ALL INSTRUCTIONSTHOROUGHLY BEFORE ATTEMPTING TO INSTALL, OPERATE OR SERVICE THE DETROITRADIANT PRODUCTS COMPANY HEATER. FAILURE TO COMPLY WITH THESEWARNINGS AND INSTRUCTIONS, AND THOSE ON THE HEATER, COULD RESULT INPERSONAL INJURY, DEATH, FIRE, ASPHYXIATION AND/OR PROPERTY DAMAGE.RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE.

CAUTION! Heater may be hot. Do not store or use gasoline or other flammablevapors and liquids in the vicinity of this or any other appliance. Note presence offlammable gas and electrical shock hazard.

WARNING! Extinguish open flame while servicing heaters. Test for gas leaks withsoap and water solution only. Wear safety glasses while servicing unit.

Approval Standards and Certifications

Detroit Radiant Products units comply with or are certified by the following Organizations orStandards:

- American National Standards (ANSI Z83.6)- Occupational Safety and Health Act (OSHA)- American Gas Association (AGA)- International Approval Services (IAS)

FOR YOUR SAFETY!

IF YOU SMELL GAS:1. Open windows.2. Do not touch electrical switches.3. Extinguish any open flame.4. Immediately call your gas supplier.

SHUTDOWN INSTRUCTIONS!

1. Open electrical circuit.

2. Rotate heater’s manual gasvalve knob to “OFF” position.

IMPORTANT: Any alteration of the system or of the factory-authorized components specified eitherin this manual or by Detroit Radiant Products Company voids all certification and warranties.

WARNING!

This is not an explosion-proof heater. Where thereis the possibility of exposure to flammable vapors,consult the local fire marshal, the fire insurancecarrier and other authorities for approval of theproposed installation.

WARNING!

NOT FOR RESIDENTIAL USE!

Do not use in the home, sleeping quarters,attached garages, etc.

2

WARNING!Do not operate heater with any part bypassed,with any part failed or in any scenario that maycompromise safety.

Warnings

Maintain all clearances to combustibles at all times!See page 5 for clearance to combustibles guidelines.

This infrared heater is designed for use in industrial and commercial buildings such as warehouses,manufacturing plants, aircraft hangars, service garages, etc.

Detroit Radiant Products Company cannot anticipate every use which may be made of their heaters.Check with your local fire safety authority if you have questions about local regulations.

This heater must be installed and serviced bytrained gas installation and service personnel only.Read and understand these instructions thoroughlybefore attempting to install, operate or service thisheater. Failure to comply could result in personalinjury, asphyxiation, death, fire, and/or propertydamage. Retain these instructions for futurereference.

WARNING!

Tube Heater Vacuum System

Any alteration of the system or of factory-authorized components specified in this manualor by Detroit Radiant Products Company voidsall certification and warranties.

IMPORTANT!

4. OPERATION

4.1 Electrical Requirements

1. The system operates on 120V, 60 Hz.

2. The system must be grounded in accordance with theNational Electrical Code NFPA 70 latest edition.

3. The system must be installed in accordance with thetypical wiring diagrams (see Figures 4-1 & 4-2).

4. Figure 4-3 illustrates the wiring of a PB series pumpassembly.

5. All systems are two-stage heat systems and will beoperated by a two-stage controller.

6. Check vacuum pump to ensure wiring is correct for properfan wheel rotation. Check directional arrow on pumphousing for proper wheel rotation.

7. The amperage draws for the individual HLV componentsare as follows. The circuit(s) must be sufficient to handlethe starting current of the buner control boxes and therunning amperage of the pump.

4.2 Burner Lighting Instructions

1. Purge main gas supply line.

2. Rotate burner’s manual gas valve knob to the “ON”position.

3. Close electrical circuit.

4. If burner fails to light, turn off gas and wait five minutesbefore repeating the above procedure.

4.3 Burner Shutdown Instructions

1. Open electrical circuit.

2. Rotate burner’s manual gas valve to the “OFF” position.

25

Operation

HLV VACUUM PUMPS

RUNNING CIRCUIT

(amp)

NC-7 2.2

PB-8 7.6

PB-9 9.6

PB-10A 11.4

STARTING RUNNING

1.0 0.2

HLV BURNER CONTROL BOX CIRCUIT (amp)

4.4 Theory of Operation

Starting Circuit (Figures 4.1 and 4.2)

There is constant line voltage sitting at both the vacuum pumpand burner(s). When the thermostat closes it sends power torelays at both the vacuum pump and burner(s).

At the vacuum pump, the relay closes to allow a completedcircuit across L1 and L2.

At the burner control box negative air pressure generated bythe vacuum pump will cause the normally open differentialswitch to close. A low voltage circuit is completed from thesecondary side of the transformer through the relay andpressure switch to the control module. The hot surface igniteris now immediately powered. After the ignitor has beenpowered for 4-5 seconds, the control causes the gas valve toopen and then initiates a 15 second ignition trial.

Running Circuit

After ignition, the flame rod monitors the flame. As long as aflame is present, the valve is held open. If proof of flame is notestablished within 15 seconds, the unit will attempt ignitiontwo more times and then lock out. If lockout occurs, thecontrol can be reset by briefly interrupting the power source.

If the flame is established for a period of time and then lost,the control acts to close the valve within one second, and anew trial sequence identical to that at start-up is initiated.

W MV1 GND

LIGHT

BK

C

BKLIGHT

R

O

HI M

BK

R

T-STAT TERMINAL

L1

W

RELAY BOARD

OY

BL

120V-240V AC

PRESSURE SWITCH

TRITON 2465HIGNITION MODULE

S1 L1 L2 S2FC1 FC2

BK

BL

24VY

120V

LIGHT

P

W

BK

G

IGNITOR

BK

ROD

BK

W

FLAME

BK

BK

L2

T'STATTERMINAL

120VAC

TRITON 2465HIGNITION MODULE

S1 L1 L2 S2

W

120-240 / 24VTRANSFORMER

L2

L1

W

BK

BK

RELAY BOARD

Y

RO

120-240V

W

Y

24V

Y

Y

R

PRESSURE SWITCH

BL

A B

C D

BL

TERMINALBLOCK

INDICATOR LIGHTS

Y

O

G

Y

Y Y

FC1 FC2

ON

GAS VALVE

HI

PM C

GY

C

PH

IM

OF

F

BURNERFLAME

W MV1 GND

BK

ROD

W

BK

IGNITOR

Figure 4-1 Block Wiring Diagram

Figure 4-2 Ladder Wiring Diagram

26

Tube Heater Vacuum SystemInternal Wiring for Burner Control Box

BL

120V

/230

V

TR

AN

SF

OR

ME

R

24V COILGY

24V INPUT FOR ZONE #1

COM

NO

NC

R

GW

O

CO

M

NO NC

BL

24V COIL

BL

24V INPUT FOR ZONE #2 IF USED

BL

GY

COM

BL

O

Y

24V

W

NO NC

G

R

G

120V/230VL2

L1

R FUSE R

27

Internal Wiring for Pump & Panel Assembly

Installation

Figure 4-3

VACUUM PUMP CONTROL BOX

(MOUNTED TO PUMP)

120

V

24V

24V IN

L2

COMMON

-

24V OUT - STAGE 2 (HIGH FIRE)

24V OUT - STAGE 1 (LOW FIRE)

24V IN

24V TWO-STAGE CONTROLLER

EXTERNALTRANSFORMER

24V

+

L1

120

V

1N 2

N 1 2

COMMON

-

L2

24V INPUT FOR ZONE

#1

N 1 2

2N 1

2N 1

N 1 2

EXTERNALTRANSFORMER

24V TWO-STAGE CONTROLLER

24V OUT - STAGE 2 (HIGH FIRE)

24V OUT - STAGE 1 (LOW FIRE)

21N

N 1 2

+

L1

THIS SHOWS ADDITIONAL WIRING FOR SYSTEMS THAT WILL OPERATE ON TWO

TEMPERATURE ZONESNOTE: DO NOT EXCEED THE TOTAL

NUMBER OF BURNERS ALLOWED PER SYSTEM AS STATED IN THE PUMP

APPLICATION GUIDELINES

N 1 2

24V INPUT FOR ZONE

#2 (IF USED)

A COMMON WIRE IS REQUIRED FOR THERMOSTATS THAT

REQUIRE CONSTANT POWER

A COMMON WIRE IS REQUIRED FOR THERMOSTATS THAT

REQUIRE CONSTANT POWER

Zone 1 Burner(s)

Zone 2 Burner(s) (if secondheat zone is to be used)

28

Tube Heater Vacuum SystemSystem Field Wiring

Figure 4-4

4.5 System Start-Up and Damper Setting

1. Recheck installation of gas piping, electrical, etc.

2. Preset primary and secondary dampers to half open.

3. Unassisted outside combustion air ducts (if required) mustbe installed before start-up.

4. Fan assisted outside combustion air ducts (if used) mustnot be connected to control box upon initial start-up.

5. To set the dampers, the system must be run for 20minutes in High Fire Mode. Check to make sure all lightson the burner control are on .

6. All dampers in the system are initially set to half closed.If a burner does not light and stay lit, the damper for thatburner will need to be adjusted to get the burner to lightfor the initial 20 miniute start-up.

29

7. Using a manometer with an adequate range, measurethe vacuum at the burner (Figure 4-5) farthest away fromthe vacuum pump. Adjust the primary damper at thepump until the manometer reaches the specified readingshown in the chart below.

8. If secondary dampers have been installed in the system,connect manometer to the designated burner and setsecondary damper to the specified reading shown in thechart below.

9. All dampers must now be readjusted a second time inthe same order. Lock the dampers in place.

BTU Rating

50,000 - 60,000 +/-.0175,000 - 110,000 +/-.01120,000 - 180,000 +/-.01200,000 - 225,000 +/-.01

-0.22-0.19

Box Pressure (inches W.C.)

-0.51-0.19

Each system damper must be adjustedto obtain the following box pressure.The systems must be operating for aminimum of 20 minutes before adjustingthe dampers to the following setpoints.

Operation

Burner Control Box

Vacuum Port

When measuring box pressure, make certain burner box lid is tightened securely.

Figure 4-5

30

5. MAINTENANCE

The HLV Series Vacuum System requires basic maintenanceto keep it operating at peak performance. This system requiresno filters to be replaced.

1. Routinely inspect the vent intakes and vent exhausts fordirt and/or obstructions. If dirt becomes a problem,installation of outside air intake ducts for combustion arerecommended.

2. Keep the aluminum reflectors clean using a light soapand water solution. Use a metal polish if reflectors areseverely dirty. Maintenance of the reflectors can varysignificantly depending on the environment.

Tube Heater Vacuum System

3. Annually inspect the exhauster system for abnormalnoise. Consult factory for troubeshooting.

4. Periodically check the integrity of the combustion tubeand heat exchangers. Replace if there are signs ofstructural failure.

Date Maintenance Performed Replacement Components Requied

31

5.1 Troubleshooting Chart

Maintenance

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

1. Blow n fuse. 1. Replace.

2. Defective thermostat. 2. Replace.

3. Defective vacuum pump relay. 3. Replace.

4. Loose or disconnected w ire. 4. Repair as required.

5. Defective vacuum pump. 5. Repair or replace.

1. Low vacuum pressure setting. 1. Adjust burner box to proper specif ied pressure.

2. Loose or disconnected w iring. 2. Replair as needed.

3. Plugged or resrticted exhaust vent. 3. Clean.

4. Plugged vacuum pressure sw itch lines. 4. Clean or replace.

5. Defective circuit control. 5. Replace.

1. Defective glo-bar. 1. Replace.

2. Loose or disconnected w ire. 2. Repair or replace.

3. Defective circuit control. 3. Replace.

1. System not grounded. 1. Connect electrical ground.

2. Defective circuit control. 2. Replace.

3. Vacuum pressure setting incorrect. 3. Adjust.

4. Low gas inlet pressure. 4. Provide required gas pressure.

5. Restricted air inlet. 5. Clean

1. Low gas inlet 1. Provide required gas pressure.

2. Defective vacuum pressure sw itch. 2. Replace.

3. Restricted air inlet. 3. Clean.

4. Vacuum pressure set incorrectly. 4. Adjust

Thermostat closed. Ignition occurs. Burner cycles off and w ill not recycle.

Thermostat closed. Ignition occurs. Burner cycles off and w ill not recycle.

General Trouble Shooting Chart

Thermostat closed but nothing happens.

Thermostat closed. Vacuum pump operates. Vacuum indicating light off.

Thermostat closed. Vacuum pump operates. Vacuum indicating light on. No glo-bar energization.

Turn up thermostat.

Does the exhausterfan turn on?

YES

NO

Does the igniterwarm up and glow

orange?

Is the incoming power atthe exhauster panel

assembly 120V/240V?

NO Is there 120V/240Vgoing to the burner

control box?

NO

Find the source of theelectrical problem.

YES Is 24V being supplied tothe exhauster panelassembly from the

thermostat?

NO

Find the source of theelectrical problem.

YES Is 24V being suppliedfrom the thermostat to

the terminal plug on thecontrol box?

YES

NO

Find the source of theelectrical problem

between the thermostatand the control box.

NO

Find the source of the electrical problem betweenthe thermostat and the panel assembly.

YES Is there 120V/240Vleaving the panel and

going to the exhauster?

YES

The exhauster may be faultyand may need replacing.

NOCheck the fuse in the

panel assembly. Is thefuse blown?

YES

Replace the fuseafter checking that

there is no probablecause such as

difficulty in rotatingthe fan wheel.

NO

Is there 24V coming off thesecondary side of the transformer

in the panel assembly?

YES

Replacetransformer.

NO

There may be afaulty relay in thepanel assembly.Consult factory.

Is the igniter physicallydamaged?

YES

Replace igniter.

NO

Check voltage at ingniter duringthe ignition sequence (usually 5seconds after power to burner

control box). Is it 24V?

YESNO

Is the resistance throughthe igniter 1 to 6 ohms?

Is the inlet or the outlet ofthe unit obstructed? Ie.ice, bird’s nest, dirt, etc.

NO YES

ReplaceIgniter.

Replace faultywiring.

YES

Removeobstruction.

NO

Check for loose wiring orrestrictions in hose connections

to the pressure switch.Are they ok?

Repair wiring orhose connections.

NO

YES

The heater is equipped with a safety pressure switch.The switch is a normally open switch an located inthe gas valve compartment. Temporarily place ajumper across the terminal of the switch. Be sure toreinstall the cover. Does the igniter glow orange?

Check the damper setting for theproper box pressures after theheater has run for 20 minutes.

Are the settings correct?

NOYES

Adjust dampersto achieveproper boxpressure.

YES

Replace the switch after verifying the following:* Baffle(s) is in the proper tube(s).* Heater, fan blower, squirrel cage, intake and exhaust are kept clean and free

from dirt and obstructions.* There is not a negative pressure experienced at the area of intake (ie: attic

space, high winds, very tight building).* The intake pipe exceeds the the maximum specifications.

NO

HLV SERIES TROUBLESHOOTING FLOWCHART

YES

Tube Heater V

acuum S

ystem Installation, O

peration, Maintenance and P

arts Manual

32

After the igniter iswarmed up, does

the gas valve open?

NO

YES

Press reset switch (if any)on transformer. If there isstill no 24V signal, replace

bad transformer.

Check voltage of internaltransformer of burner box.Is there 24V coming off the

secondary side?

Is there a 24V signal across L1and ground at the circuit board?

YES Replace badcircuit board.

Test for 24V at valveduring valve opening

period (usually 5seconds after power

to the heater). Isthere 24V to valve?

NO

NOPossibly, the circuit board and/orwiring harness is faulty. These

should be replaced.

YES

Check to make sure gas pressure iswithin minimum and maximum inputs,as indicated on AGA burner rating

label. Is gas pressure OK?

Replace gasvalve.

Correctproblem.

NO

YES

Does theburner light?

YES

NOIs the gas cock in the ON position?

Check to make sure gas pressure iswithin minimum and maximum inputs,as indicated on AGA burner rating

label. Is gas pressure OK?

YES

YES

NO

Make sure gaslines were

purged of air.

Correctproblem.

YES

Does the burnerstay on?

NO Does the burner stay on for approx.15 seconds and then shut off? YES

Is the heater properlygrounded? Is thepolarity correct? If

NO, correct problem.

YES

Certain models have a separate glo-barigniter and flame rod sensor located next tothe glo-bar. Other models have a glo-barigniter only, which acts as both an igniterand flame sensor. Does model in questionhave glo-bar ignitor only?

YES

Does the heater stay onuntil call for heat ends?

YES NO* Improper grounding.* High winds.* Taking combustion air

from the attic.* Dirty environment.* Baffle not located

properly.* Fluctuating gas

pressure.

The following can causethe heater to shut down:

Troubleshootingends.

NO

Exhaustpressure switchmay be faulty or

there is arestriction in the

exhaust.

Check to make sure that thepressure is within minimumand maximum inputs asindicated on AGA burnerrating label. Is gas pressureOK? If NO, correct problem.

Does the burnercome on and thenturn off immediately(1 or 2 seconds)?

Sensing rod is faulty or flame isweak. Check to make sure heateris operating at proper gaspressure as indicated on AGAburner rating label and thenreplace sensing rod if needed.

Consultfactory for

proper parts.

With ammeter, check amperage at flame rod.Is it greater than 7 micro amps?

Check to make sureflame sensor wire isOK and then replace

circuit board.

YES

NO

YES

YES

NOYES NO

Tube Heater V

acuum S

ystem Installation, O

peration, Maintenance and P

arts Manual

33

217

33B

68A

31B

44

122

832

329

1502

828

841

208

7621

2

840

200

223

204

201

303

825

83

31B

1526

304

70

1251

56C

218

NO

PS

1

220

V24

V57

A

V23

V55

A V56

A

222

109

12

1250

1254

11

1289

CO

M

832

1528

1527

NO

24

V

CO

IL

NO NC

COM

NC

NC

NO

CO

M

24

V

CO

ILTRANSFORMER

24V

FU

SE

120V/230V

1565

1526

1530

1566

V30

1

V30

2

Com

bust

ion

Cha

mbe

r

106

1202

19B

21B

26A

26B

82

105

20C

Emitt

er T

ube(

s)

65I

21B

220

26A

1216

V30

3

801

566

17

97 5

34

5.3 Parts List

Tube Heater Vacuum SystemTube Heater Vacuum System Installation, Operation, Maintenance and Parts Manual

Parts L

ist

35

HLV SERIES PARTS LISTING

Tube Heater V

acuum S

ystem Installation, O

peration, Maintenance and P

arts Manual

TP# ITEM TP# ITEMTP-1 CONTROL BOX COVER TP-303 RIGHT END PANEL TP-5 FLANGE GASKET TP-304 CONTROL BOX TP-9 CONDUIT COUPLING TP-329 1/4" NEUTRAL TERMINAL BLOCKTP-10 CONDUIT 4" X 1/2" TP-566 VENT LIMITING ORIFICETP-11 IGNITOR BOX TP-801 CENTER PANELTP-12 IGNITOR BOX COVER TP-825 24V ISOLATION RELAY BOARDTP-17 SIGHT GLASS KIT TP-828 OPERATIONAL INDICATOR LIGHTSTP-19B 4" TUBE & REFLECTOR HANGER W/ SPRING CLIP TP-832 THERMOSTAT TERMINAL STRIPTP-20C 120" REFLECTOR TP-840 36E96-224 24V NAT. GAS VALVE - 1/2"TP-21B TUBE CLAMP TP-841 36E96-226 24V LP GAS VALVE - 1/2"TP-26A 10 FT. RADIANT TUBE STRAIGHT TP-1202 16'' BURNER TUBE WITH FLANGETP-26B 10 FT. RADIANT TUBE STRAIGHT (AL-TI) TP-1216 NC-7 EXHAUSTER PUMPTP-31B CONTROL BOX BRACKET TP-1250 24V IGNITER TP-33B 1/2" GAS COCK TP-1251 TRITON 2465H CIRCUIT BOARDTP-44 AIR ORIFICE W/SCREEN - CONSULT FACTORY TP-1254 IGNITER GASKETTP-56C 1/4" PRESSURE TUBE - CONSULT FACTORY TP-1289 EXHAUSTER MOUNTING TUBE FOR NC-7 PUMPTP-65I 33" INTERLOCKING BAFFLE TP-1502 HLV LEFT END PANELTP-68A STRAIN RELIEF BUSHING TP-1526 75VA TRANSFORMER W/ FOOT MOUNTSTP-70 CONTROL BOX COVER GASKET (PER FOOT) TP-1527 24V SWITCHING CONTROL RELAYTP-76 RUBBER GROMMET TP-1528 EXHAUSTER POST PURGE RELAYTP-82 REFLECTOR CENTER SUPPORT TP-1530 FUSE HOLDERTP-83 STAINLESS STEEL FLEX CONNECTOR TP-1565 8" X 8" ELECTRICAL BOXTP-97 1/4" X 1/4" BRASS INT./EXT. ATMOS. BARB FITTING TP-1566 EXHAUSTER CONTROL PANEL ASSEMBLY w/ Electrical ComponentsTP-105 REFLECTOR END CAP TP-NOPS NORM. OPEN DIFFERENTIAL PRESSURE SWITCHESTP-106 REFLECTOR CLIP (TP-61B) N.O. Differential Pressure Switch (50 TO 80MBTU/H)TP-122 GASKET FOR AIR ORIFICE & AIR COLLAR (TP-61E) N.O. Differential Pressure Switch (90 TO 125MBTU/H)TP-200 BURNER (50 TO 100MBTU/H LP GAS) (TP-1261A) N.O. Differential Pressure Switch (140 TO 180MBTU/H)TP-201 BURNER (125 TO 225 MBTU/H NAT OR LP GAS) (TP-1061A) N.O. Differential Pressure Switch (200 TO 225MBTU/H)TP-204 GAS ORIFICE - CONSULT FACTORY V-23 ISOLATION BOOTTP-208 "Z" MOUNTING BRACKET V-24 WORM GEAR CLAMPTP-212 1/2" X 3" PIPE NIPPLE V-55A 4" ADAPTERTP-217 PRESSURE BARB FITTING V-56A 5" ADAPTERTP-218 EXHAUST PRESSURE TUBE (VINYL) V-57A 6" ADAPTERTP-220 STAIN. STL. TUBE CLAMP (175 & 225 MBTU/H) V-301 PB-8 PUMP ONLYTP-222 FLAME ROD V-302 PB-9 PUMP ONLYTP-222A FLAME ROD WIRE V-303 PB-10A PUMP ONLYTP-223 GAS MANIFOLD