the apex range - mtneri.com · 10 2 aph-ch046 gear clamp table 3: burner box and heat exchanger....

Installation, Operation and Service Instructions

THE APEX RANGEULTRA EFFICIENCYTWO STAGE INFRARED HEATER

WARNINGS

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. If you smell gas: 1. Open windows 2. Don’t touch electrical switches 3. Extinguish any open flame4. Immediately call your gas supplier

OWNER

Retain this Manual & ensure available for service. Improper installation, adjustment, alteration, service or maintenance can cause injury, death or property damage.

Read the installation, operation and service instructions thoroughly before installing or servicing this equipment.

INSTALLER

Provide Manual to Owner upon completion of installation!

Read and thoroughly understand these Instructions before attempting any installation

CAUTION: FIRE OR EXPLOSION HAZARD

Maintain clearance to combustible constructions as further specified in this manual. Failure to do so could result in a serious fire hazard. Heaters should not be located in hazardous atmospheres containing flammable vapors or combustible dusts. Signs should be provided in storage areas specifying maximum safe stacking height.

CAUTION: MECHANCIAL HAZARD

This equipment expands and contracts with each operating cycle. The gas connection, suspension hardware and the installation itself must safely allow this movement. Failure to do so could result in serious fire or explosion hazard.

CAUTION: FIRE OR EXPLOSION HAZARD

This heater is equipped with an automatic ignition device. Do not attempt to light the burner by hand. Failure to comply could result in a serious fire and personal injury hazard.

CAUTION: MECHANCIAL HAZARD

Do not use high pressure (above 1/2 psi) to test the gas supply system with the burners connected, doing so could result in damage to the burner and its control components requiring replacement.

Do not install equipment in atmospheres containing halogenated hydrocarbons or other corrosive chemicals, doing so may lead to premature equipment failure and invalidation of the warranty. Additionally, it is recommended that the equipment be installed with a slope downward and away from the burner of ¼" (6mm) in 10' (3m) to allow start-up condensate drainage.

CAUTION: SERVICE LIFE RISK

Due to continuous product innovations, we reserve the right to change product specifications without due notice.

CONTENTSINTRODUCTION ............................................................................................................................. 1

Installation Codes .............................................................................................................................................1GENERAL SPECIFICATIONS .......................................................................................................... 2DIMENSIONAL CHARTS ................................................................................................................ 3CONFIGURATION ........................................................................................................................... 3PACKAGING CONTENTS ............................................................................................................... 4

General Assembly ............................................................................................................................................4Burner Box and Heat Exchanger .....................................................................................................................5

CLEARANCE TO COMBUSTIBLES ................................................................................................. 6HANGERS INSTALLATION AND HEATER SUSPENSION ............................................................... 7VENTING & COMBUSTION AIR ...................................................................................................... 8

General Requirements .....................................................................................................................................8Polypropylene Vent System .............................................................................................................................8General Rules for Vent Terminals ....................................................................................................................8Condensation Management ............................................................................................................................9Unvented Operation ..........................................................................................................................................9Combustion Air Supply (Optional) ...................................................................................................................9Venting Configurations ..................................................................................................................................10

GAS PIPING .................................................................................................................................. 12General REquirements ...................................................................................................................................12

ELECTRICAL WIRING ................................................................................................................... 13Wiring Diagram ..............................................................................................................................................13High Limit Controls ........................................................................................................................................14Ignition Control Module Error Codes ...................................................................................................................... 14

BURNER OPERATION ................................................................................................................... 15Starting Sequence of Operation ....................................................................................................................15Maintenance ...................................................................................................................................................15

ASSEMBLY INSTRUCTIONS SEQUENCE ..................................................................................... 16Assembly Preparation ....................................................................................................................................17Tubes, Hanging Brackets and Baffles Assembly .........................................................................................18Reflectors Assembly .................................................................................................................................... 20Canopy and End Caps Assembly...................................................................................................................21Burner Box and Heat Exchanger Installation ............................................................................................... 24Gas and Vent Installation .............................................................................................................................. 24

INSTALLATION CHECKLIST ........................................................................................................ 25TROUBLESHOOTING ................................................................................................................... 26

Troubleshooting Chart .................................................................................................................................. 27REPLACEMENT PARTS ............................................................................................................... 28WARRANTY .................................................................................................................................. 29

The APEX Range AX-LT199_02272017al

Advanced Radiant Systems is proud to introduce the highest efficiency, indirect fired radiant heater on the market today. The APEX Range is the pinnacle in infrared heating. It boasts the highest radiant output and thermal efficiency of any radiant tube heater in the world! Its pioneering design incorporates dual firing rates to optimize control and comfort while minimizing energy consumption. It is also the first unitary heater with flue temperatures low enough for venting with Polypropylene pipe system. Other design features include twin 100% parabolic reflectors enclosed by a single canopy to ensure minimal convective heat loss. The APEX range also includes the Energy Recovery Exchanger (ERX) module to maximize thermal and radiant efficiency. The twin fans and the two stage gas valve ensure optimal efficiency at both high and low firing rates. For energy conservation, quality and performance, the APEX range truly has no equal.

IMPORTANT The manufacturer’s instructions, the layout drawing, national and local codes and ordinances, and all applicable standards which apply to gas piping and electrical wiring comprise the basic information needed to complete the installation. These criteria must be thoroughly understood before proceeding. Only personnel who have been trained and understand all applicable codes should undertake the installation. Manufacturer representatives are Factory Certified in the service and application of this equipment and can be called on for helpful suggestions about installation.

Installation CodesInstallations must comply with local building codes, or in their absence, the latest edition of the national regulations and procedures as listed below.

General Installation and Gas CodesHeaters must be installed only for use with the type of gas appearing on the rating plate, and the installation must conform to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 in the US and CSA B149.1 Installation Codes in Canada. Not for use in residential dwellings, refer to Rating plate.

Aircraft Hangar InstallationInstallation in aircraft hangars must conform to the Standard for Aircraft Hangars, ANSI/NFPA 409 in the US and CSA B149.1 Installation Codes in Canada.

Public Garage Installation Installation in public garages must conform to the Standard for Parking Structures, NFPA-88A or Standard for Repair Garages, NFPA 88B, in the US and CSA B149.1 Installation Codes in Canada.

Parking Structures Technical requirements are outlined in ANSI/NFPA 88B (USA)

Gas Supply Lines Gas supply pipe sizing must be in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 in the US and CSA B149.1 Installation Codes in Canada. A 1/8 in NPT plugged tap must be installed in the gas line connection immediately upstream of the burner farthest from the gas supply meter to allow checking of system gas pressure.

Electrical All heaters must be electrically grounded in accordance with the National Electric Code, ANSI/NFPA 70 in the US, and the Canadian Electric Code, CSA C22.1 in Canada, and must comply with all local requirements.

INTRODUCTION


GENERAL SPECIFICATIONS

Gas SupplyInlet Pressure Natural Gas: Minimum 5.0" W.C. (1.2 kPa) Maximum 14.0" W.C. (3.5 kPa)

Manifold Pressure Natural Gas: 3.5" W.C. (0.9kPa) (High Rate) 2.4" W.C. (0.6kPa) (Low Rate) Inlet Connection Natural Gas: 1/2" NPT

Electric Supply 120 VAC, 60 HZ, 1 Amp: 36" (90cm) cord with grounded 3 prong plug

Flue and Outside Air Connection4" (110mm) plastic flue adapter and connection for outside air (optional) provided at the heater


DIMENSIONAL CHARTS

MODEL HIGH RATE (btu/hr)

LOW RATE (btu/hr)

HEAT EXCHANGER

LENGTH ft (m)BAFFLE

ft (m)

AX-140N 135,000 85,000 40 (12) 18 (5.4)

A

A

1

1

2

2

3

3

4

4

A A

B B

SIZE DWG NO REV

SCALE SHEET OF

DRAWNREVISIONS

No. APPD

FIG 1

1 1 0B

jwu 12/10/2015

THE-140NGENERAL ASSEMBLY

N.T.S.

TOLERANCES: UNLESS OTHERWISE INDICATED< 6

± 0.1< 0.25

± 0.004

> 30to 120

± 0.3

± 0.012

> 0.25to 1

> 6to 30

± 0.2> 1to 5

± 0.008

> 120to 315

± 0.5> 5to 12± 0.02

> 12to 40

> 315to 1000

± 0.8

± 0.03

> 1000to 2000

± 1.2> 40to 80± 0.05

> 2000to 4000

± 2> 80to 160± 0.08

> 4000

± 3> 160

± 0.12inch

es

THIS DRAWING IS CONFIDENTIAL AND IS THE PROPERTY OF SUPERIOR RADIANT PRODUCTS. UNAUTHORIZED USE OF THISDRAWING IS FORBIDDEN.

ECR#

milli

met

ers

DATE BY

M/D/Y

DESCRIPTION0 ISSUED FOR CONSTRUCTION12

12/10/2015 JW J.STARK.

angu

lar

1

DIMENSIONS - CRITICAL TO QUALITY

- MUST BE RoHS COMPLAINT

NOTES

34" (

864m

m)

34" (864mm)

12" (

305m

m)

14" (

356m

m)

287" (7280mm)

Figure 1: Overall Dimensional Information

CONFIGURATION

Table 1: Configuration Information


PACKAGING CONTENTS

6

22

15 14

7

3

5

12

21

1311

1810

20

16

1

4

8

9

19

17

2

Figure 2: General Overview - Refer to Table 2

General Assembly

REF NO. QTY PART NO. DESCRIPTION1 1 APR-CR102 Canopy, burner section2 1 APR-CR103 Canopy, middle section3 1 APR-CR115 Canopy u-tube section4 4 APR-CR117 Reflectors5 4 APR-CR114 Reflector separator6 1 APR-CR122 U-tube Reflector7 1 APR-CR123 Seal8 1 APR-CR104 Canopy end cap, burner side9 2 R-CR118 Small end Cap

10 2 T-UT002 Tube with flange11 2 T-CT001 Tube12 1 APT-CT016 SS baffle with tab13 2 APT-CT007 & APT-CT006 Baffle & Baffle Extension14 1 APR-CR119 U-tube reflector end cap15 1 APR-CR105 End cap, u-tube side16 3 APR-CR124 Reflector bottom cover17 8 APH-UH083 U-bolt18 4 APBK-CR116A Hanger Assembly19 1 APX-CS113 Heat Exchanger Assembly20 1 APB-CX14N Burner Housing Assembly21 4 APTC-CR010 Coupling Assembly22 1 APTU-CT120 U-Tube, 4"

Table 2: General Assembly


PACKAGING CONTENTS

44

3

8

7

5

6

2

1

9

10

10

Figure 3: Burner Box and Heat Exchange - Refer to Table 3

Burner Box and Heat Exchanger

REF NO. QTY PART NO. DESCRIPTION1 1 APB-AX14N Burner housing assembly

2 1 APH-CS122 Heat exchanger housing assembly

3 1 APV-CT122 Adaptor

4 2 APH-CH001 Gasket

5 1 APH-CE279 Temperature switch

6 1 APH-CE273 + APH-CE274 Cable connector

7 1 APF-CE229 Burner blower

8 1 APF-CE277 Heat exchanger blower

9 1 APH-CH231 Flex hose

10 2 APH-CH046 Gear clampTable 3: Burner Box and Heat Exchanger


CLEARANCE TO COMBUSTIBLESA general clearance of 18 in (46 cm) in every direction is recommended for servicing. In addition to this it is very important to observe the minimum clearance to combustibles at all times to avoid any possibility of property damage or personal injury.

WARNING • Clearances as marked on the heater body must be maintained from vehicles parked beneath. Signs should

be posted identifying any possible violation of the clearance distances from the heater in all vehicle areas.

• Maximum allowable stacking height in storage areas should be identified with signs or appropriate markings adjacent to the thermostat or in a conspicuous location.

• Clearance to combustibles DO NOT indicate acceptable distances from PVC paneling. Refer to panel manufacturers recommendations.

Combustible materials are considered to be wood, compressed paper, plant fibers, plastics, Plexiglas or other materials capable of being ignited and burned. Such materials shall be considered combustible even though flameproofed, fire-retardant treated or plastered. Adequate clearance to sprinkler heads must be maintained (NFPA 13: Standard for the Installation of Sprinkler Systems).The stated clearance to combustibles represents a surface temperature of 90°F (32°C) above room temperature. It is the installer’s responsibility to ensure that adjacent materials are protected from deterioration.

CLEARANCE TO COMBUSTIBLES in (cm)A B C D E

Vented 91 (231) 40 (102) 4 (10) 23 (58) 21 (53)

Unvented 91 (231) 40 (102) 4 (10) 45 (114) 21 (53)*Refer to figure 4 for component identification

C

A

B

D

B

E

Figure 4: Clearance to Combustibles

Table 4: Minimum Clearance to Combustibles


HANGERS INSTALLATION AND HEATER SUSPENSION • Suspension mechanism must allow for lateral tubing expansion. A minimum 12 in (30 cm) length welded

link chain with a working load limit of at least 200 lbs. is recommended (refer to Figure 5 for more details). Manufacturer recommends and makes available “quick links” for connecting chain. If any open ended “S” hooks and turnbuckles are used, the open ends must be closed to avoid unhooking chain with inadvertent contact.

• Locate hanging chain at predetermined suspension points in the structure.

• It is recommended that the heater is raised to its final position once the assembly has been completed.

I-BEAM

I-BEAMCONCRETE BEAM

TRUSS

24" M

IN. BEAM CLAMP

38"THREADEDROD

TURNBUCKLE

NOTE:CLOSE ALL QUICK LINKS OR"S" HOOKS, CHAIN LINKS,"J" BOLTS ANDTURNBUCKLES OR ANYOPEN CONNECTION.

ANCHOR

CHAIN LINK

12" M

IN.

12" M

IN.

EYE BOLT

HANGERS INSTALLATION- SUSPENSION MECHANISM MUST ALLOW FOR LATERAL TUBING EXPANSIONS. A MINIMUM 12" LENGTH WELDED LINK CHAIN WITH A WORKING LOAD LIMIT OF AT LEAST 200 LBS. IS

Figure 5: Suspension Mechanism

NOTE: ENSURE THAT THE MOUNTING HEIGHTALLOWS A DOWNWARD SLOPE OF 1

2" (13MM)TOWARDS THE

NOTE: BOTH METHODS ARE ACCEPTABLE. ENSURETHAT THE HANGING BRACKETS ARE LEVELED

VERTICAL SUSPENSION CHAINS

Figure 6. Heater Suspension.


IMPORTANT——Maximum total exhaust vent length allowed for this heater: 4 in (110 mm) venting 12 ft (3.7 m) and 6 in (150 mm) venting 25 ft (7.6 m), plus up to two 87° elbows and vent terminal (45° elbow with bird screen).

——Maximum total fresh air inlet duct length allowed for this heater: 4 in (110 mm) duct 12 ft (3.7 m) and 6 in (150 mm) duct 25 ft (7.6 m), plus up to two 87° elbows and air inlet terminal (45° elbow with bird screen).

——Total of vent length plus outside air supply duct length cannot exceed 25 ft (7.6 m) on 4 in (110 mm) venting and 50 ft (15.2 m) on 6 in (150 mm) venting.

——Note: The above stated requirements assume a maximum of 2 elbows in the total combination of vent and air supply duct. Subtract 5 ft (1.5 m) of allowable length for each elbow if 3 or more elbows are used.

—— Install a minimum 18 in (46 cm) straight length of duct for air intake or vent before any Tee or elbow.

——Do not install any elbow or 45° fitting to bring vent lower than the horizontal tube system.

——Consult factory for use of common venting

——Follow the vent pipe manufacturer’s instructions and the instructions in this manual when installing the vent pipe.

VENTING & COMBUSTION AIRGeneral Requirements

• Refer to the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) in the US and CSA B149.1 Installation Codes in Canada, as well as all local requirements for general venting guidance.

• Heaters may be installed vented or unvented.

• Heaters may be vented horizontally or vertically.

• Optional outside air supply may be directed to the heater.

Polypropylene Vent System • The heater has been approved for a venting system, which uses a single wall, rigid, polypropylene pipe

system. The manufacturer approves vent products approved for sustained flue gases up to 230°F (110°C).

• Venting system must be installed by following the vent manufacturer’s instructions.

• Installations must comply with applicable national, state, and local codes. For Canadian installation, Polypropylene vent must be listed as a ULC-S636 approved system.

• DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

General Rules for Vent Terminals • Be not less than 7 ft (2.1 m) above grade when located adjacent to public walkways.

• Terminate at least 3 ft (0.9 m) above any forced air inlet located within 10 ft (3 m).

• Terminate at least 4 ft (120 cm) below, 4 ft (120 cm) horizontally from or 1 ft (30 cm) above any door, window, or gravity inlet into any building.

• Be located at least 12 in (30 cm) from any opening through which vent gases could enter a building.

• Extend beyond any combustible overhang.

• Be installed at a height sufficient to prevent blockage by snow.

• Vent terminal(s) and/or intake air must be a minimum of 24 in (60 cm) above any parapet, vertical wall or structure within 10 ft (3 m) horizontally.


VENTING & COMBUSTION AIRNote: In cold climates water vapor in the exhaust gases will condense into a cloud of vapor where the vent exits the building. Extending the exposed vent piping up to a maximum of 6 in (15 cm) from the wall helps vapor from being trapped along a building’s face.

Condensation Management • Heater develops some condensation in the vent piping. When using long runs of venting or when the

venting passes through cold or unheated areas, considerable amounts of condensate from the flue gases can develop.

• Condensate should drain freely from the vent system and should collect in a siphon that can be drained. A 4 in (110 mm) Flanged Drain Adaptor is supplied with heater. A siphon should be installed in the drain nipple. Fill the siphon with water before appliance start-up.

• The vent should slope towards the heater and condensate collector.

• Damage to heat exchanger and pipe vent may occur if the condensate is allowed to collect and freeze. Pooling of condensate can restrict airflow and can cause nuisance failures of the system.

• Condensate is corrosive and should be treated and disposed of according to local codes.

• If condensation in the outside air supply duct is a problem, shorten or adequately insulate the section.

Unvented Operation • Requirements for combustion air supply and dilution air vary by jurisdiction, building type and specific

installation details. See local codes for guidance. In general, fresh air ventilation must be provided to the building space at 4 cfm per 1000BTU/Hr in USA (3 cfm per 1000 BTU/Hr in Canada).

• Optional outside air supply is not recommended for unvented heaters due to possible pressure imbalances in the building space.

• Ensure that minimum combustible clearances are maintained for unvented heaters. Refer to Table 2, for required clearance dimensions.

Combustion Air Supply (Optional) • An outside combustion air supply is strongly recommended if the building space encloses a negative

pressure due to exhaust etc. or if the building contains materials which would expose the heater to halogenated hydrocarbon atmospheres.

• The outside air terminal should be located at an elevation equal to or below the vent terminal elevation to prevent back-venting of flue gases into the burner compartment.

• Install single wall pipe PP or PVC pipe.

• If installing both an intake air and vent terminal through a sidewall there must be a minimum of 36 in (90 cm) separation, measured on vertical center line, between the intake air and vent terminations.


Venting Configurations

4" PIPE - MAXIMUM LENGTH 12 FT

4" OR 6" PIPE

4" ADAPTOR(SUPPLIED)

6" PIPE - MAXIMUM LENGTH 25 FT(PLUS UP TO TWO 87L ELEBOWS

CONNECT TOTERMINAL WITHBIRD SCREEN

COLLAR

WALL

HEAT EXCHANGER

AIR INTAKE

4" TO 6" ECCENTRIC ADAPTORINSTALLATION SHOULD ALLOWCONDENSATION TO REACHTHE DRAIN POINT

FOR VENTING FOLLOW INSTALLATIONINSTRUCTIONS OF VENT MANUFACTURER

4" PIPE - MAXIMUM LENGTH 12 FT4" OR 6" PIPE

4" ADAPTOR(SUPPLIED)

6" PIPE - MAXIMUM LENGTH 25 FT(PLUS UP TO TWO 87L ELEBOWS

ROOFFLASHING

CONNECT TOTERMINAL WITHBIRD SCREEN

Maintain minimum clearance of 12" (30cm) or 18" (45cm) in Canada - Minimum clearance is above hightest anticipated snow level

BASE SUPPORTS VERTICAL SECTIONS

HEAT EXCHANGER

AIR INTAKE

4" TO 6" ECCENTRIC ADAPTORINSTALLATION SHOULD ALLOWCONDENSATION TO REACHTHE DRAIN POINT

FOR VENTING FOLLOW INSTALLATIONINSTRUCTIONS OF VENT MANUFACTURER

Horizontal Venting

Vertical Venting

Figure 7: Vented products of combustion and no-ducted air

VENTING & COMBUSTION AIR


1

1

2

2

3

3

4

4

A A

B B

Optional outside air supply is not recommended for unvented heaters due to the possible pressure imbalances in the building space.

Ensure that minimum combustible clearances are maintained for unvented heaters.

FRESH AIR

EXHAUST

Figure 8: Unvented Configuration (no external venting)

1

1

2

2

3

3

4

4

A A

B B

SIZE DWG NO REV

SCALE SHEET OF

DRAWNREVISIONS

No. APPD

FIG 7 ASSEMBLY

1 1 0B

jwu 3/24/2016

DRAWING TITLEDETAIL

N.T.S.


± 0.1< 0.25

± 0.004

> 30to 120

± 0.3

± 0.012

> 0.25to 1

> 6to 30

± 0.2> 1to 5

± 0.008

> 120to 315

± 0.5> 5to 12± 0.02

> 12to 40

> 315to 1000

± 0.8

± 0.03

> 1000to 2000

± 1.2> 40to 80± 0.05

> 2000to 4000

± 2> 80to 160± 0.08

> 4000

± 3> 160

± 0.12inch

es

THIS DRAWING ISCONFIDENTIAL AND IS THEPROPERTY OF SUPERIORRADIANT PRODUCTS.UNAUTHORIZED USE OF THISDRAWING IS FORBIDDEN.

ECR#

milli

met

ers

DATE BY

M/D/Y


JW J.STARK.

angu

lar

1

- CRITICAL TO QUALITY


NOTES

36" MINIMUM

VENT (EXHAUST TERMINAL

INTAKE AIRTERMINAL

REQUIREMENTS ARE FOR BOTH SIDE WALL PENETRATION AS WELL AS ROOF PENETRATION.

KEEP INTAKE AIR AND VENT TERMINAL BIRD SCREEN CLEAR OF DEBRIS

Figure 9: Vented products with supplied fresh air

VENTING & COMBUSTION AIR


GAS PIPING

• The gas meter and service must be sufficiently large to supply gas to the connected building gas load including the heating equipment and any other gas fired equipment. Additionally, the gas distribution piping must be designed according to local and national ordinances. Generally (low pressure) systems designed with a maximum ½ in W.C. total pressure drop meet this requirement

• Gas supply pipe sizing must be in accordance with the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) in the US and CSA B149.1 Installation Codes in Canada.

• Before connecting burners to the gas supply system, verify that high pressure testing of the system has been completed. Failure to do so may expose the burner components to damaging high pressure, requiring replacement of key components.

• In USA, use a flexible metal connector certified to ANSI Z21.24/CSA 6.10 Standard for Connectors for Gas Appliances at least ½-in dia; 24-in to 36-in in length.

• In Canada, a radiant tube type infrared heater shall be connected with a Type I hose connector certified to CAN/CGA 8.1 Standard for Elastomeric composite Hose and Hose Couplings for Conducting Propane and Natural Gas of a length of 36-in ± 6-in (90 ± 15 cm).

Flexible gas connectors of approved type must be installed as shown in Figure 10, in one plane, and without sharp bends, kinks or twists. A smooth loop of approximately 12 in (30 cm) in diameter is best. Failure to install the gas connection in the approved manner will result in a hazardous and potentially deadly situation due to the movement of the heat exchanger and burner in the normal course of operation.

3" (7.62 cm) MAX. SHUT-OFF VALVE

12"

AIR FLOW

DIRECTION

HEATER

MOVEMENT

0 - 180°

HEATER

MOVEMENT

HEATER

MOVEMENT

HEATER

MOVEMENT

HEATER

MOVEMENT

WRONG WRONG

CORRECT POSITIONS INCORRECT POSITIONS

DISPLACEMENT

Figure 10: Flexible Gas Connections

General REquirements


ELECTRICAL WIRINGWiring Diagram The heater is normally controlled by low voltage (24V) thermostats. In all cases, the heater must be grounded in accordance with the National Electric Code, ANSI/NFPA 70 in the US, and the Canadian Electric Code, CSA C22.1 in Canada, and must comply with all local requirements. The heater may also be controlled with a manual line switch or timer switch in place of the thermostat. Refer to Figure 11 for guidance on electrical wiring of heaters. If any of the original wire as supplied with the heater must be replaced, it must be replaced with wiring having a rating of at least 105°C temperature service and 600 volts capability.

Figure 11: Wiring Diagram using 24VAC Thermostat


ELECTRICAL WIRINGHigh Limit Controls

Heat Exchanger High Limit SwitchThis device is located on the heat exchanger box and limits the maximum temperature of the heat exchanger. If the flue gas temperature rises above the temperature setting, the switch opens causing the heater to shut down. The switch will auto reset once the temperature drops sufficiently.

Blower Air Pressure SwitchesThe blower/heater is equipped with an air pressure switch located in the burner box. This device is connected in series with heat exchanger high limit switch and monitors the air pressure produced by the blowers. In the event that the exhaust venting or the intake pipe becomes blocked or sufficiently restricted, the normally open air pressure switch will shut down the heater.

Ignition Control Module Error Codes

Module Codes (CNE/FENWAL)

◊ 1 FLASH Air Flow Issue

◊◊ 2 FLASHES Flame Sensor Issue

◊◊◊ 3 FLASHES Ignition Lockout (after 3 failed attempts)


BURNER OPERATIONStarting Sequence of Operation

• Turn the thermostat up. When the thermostat calls for heat, both blower motors will energize

• After the blower is running, the air-proving switch closes and activates the ignition module.

• The ignition module, after a pre-purge period of approximately 30 seconds, energizes the igniter. Then, the gas valve is energized for this ignition trial period of 15 seconds.

—• If a flame is detected, the ignition sensing rod “reads” a rectification signal and the gas valve remains open. The sparking stops when the flame signal is established. —• If no flame is detected, the gas valve closes and a 30 second inter-purge period begins. —•After the inter-purge, the module repeats the trial for an ignition period.

• If a flame is still not established, a third and final inter-purge followed by a final ignition trial cycle begins. After three trials, the module will lockout for a period of approximately 1 hour or until reset. (Reset is accomplished by removing power from the module for at least 5 seconds.) After this 1 hour period, the module re-attempts the full ignition sequence.

Note: When using a 24V thermostat, and the heat requirement has been met and the thermostat opens, the burner shuts off but the blowers will continue to run for approximately 30 seconds. This is referred to as a post purge. This allows the products of combustion to be removed from the heat exchanger to avoid nuisance condensation and increase heat exchanger life.

MaintenanceFor best performance, certain minimal maintenance procedures should be performed before each heating season:

• Installation environment and best practices should be considered in determining frequency.

• Before performing any services or maintenance, shut off gas and electrical supply to heater.

• Check condition of heat exchanger forced air blower. Dirt and dust may be blown or vacuumed from the blower.

• Check condition of heat exchanger. Dirt and dust may be blown or vacuumed from the heat exchanger core / box.

• Check condition of burner box blower by removing the flex duct. Dirt and dust may be blown or vacuumed from the blower.

• Check condition of burner. Remove any foreign objects or debris from inside the burner box or burner cup.

• Inspect the igniter. Replace igniter if there is excessive wear or erosion, breakage or other defects.

• Be sure the burner observation window is clean and free of cracks or holes. Clean or replace as necessary.

• Check the flue pipe for soot or dirt and reattach to the heater after cleaning as necessary.

• The reflector sections may be cleaned by wiping with a damp cloth.

• A service agency qualified to adjust and repair infrared heaters should be engaged for service other than routine maintenance.

• Be sure vent terminal and fresh air inlet are free from obstructions. If either pipe is restricted, the safety air switch will not operate properly, and the heater could fail to operate.

• Check the inside of the radiant tubes visually with a flashlight. If carbon or scale are present, scrape or otherwise remove deposits (a wire brush works well)


ASSEMBLY INSTRUCTIONS SEQUENCE

(4"/1

02m

m) O

/LAP

TYP

ICAL

FOR

CAN

OPY

&REF

LEC

TOR

(277

"/703

6mm

)

(74"

/188

0mm

)(7

4"/1

880m

m)

(74"

/188

0mm

)

(7"/1

78m

m)

10'/3

048m

m T

UBE

WIT

H F

LAN

G10

'/304

8mm

TU

BE W

/O F

LAN

GE

CO

UPL

ERC

OU

PLER

1.5

("/3

8mm

)

(3"/7

6mm

)

(9"/2

29m

m)

(6"/1

52m

m)

6' /

1829

mm

STA

INLE

SS S

TEEL

BAF

FLE

12'/3

658m

m B

AFFL

E

REFL

ECTO

R SE

PARA

TOR

(4)

11("/3

05m

m)

12("/3

05m

m)

(40"

/101

6mm

)(4

0"/1

016m

m)

REFL

ECTO

R BO

TTO

M C

OVE

R(3)

Figure 12: General Overview of Installation


Assembly PreparationIt is recommended that the heater is raised to its final position once the assembly has been completed.

Prior to assembly you should:◊ Read this manual thoroughly◊ Identify all the components

◊ Be familiar with the wiring diagram◊ Understand the order of assembly

Note: The reflectors/canopy flanges are sitting lower than the tubes. Assembly supports have to allow the reflector and canopy parts to slide through the hanging brackets.

1. Use proper assembly supports (4 recommended).

5⁄8"

2. Assemble hanging brackets (4 brackets).

4 x HANGER, U-Support CR106

4 x HANGER, Cross Support CR107

8 x HANGER,Brace CR108

16 x Bolt 3/8 in, 13/4 in

16 x Spring Washer

16 x Nut 3/8 in



Tubes, Hanging Brackets and Baffles Assembly

3. Locate and position tubes with flange 1 and 4 on supports.

4 X HANGING BRACKET ASSEMBLY

4 X COUPLER

TUBE WITHOUT FLANGE

4 X ASSEMBLY SUPPORTS

TUBE WITH FLANGE

4. Install couplers between tubes. When installing, orient band clamp lock bolts to top, at 10 o’clock or 2 o’clock position. TUBE WELD SEAM

When installing: Orient band clamp lock bolts to top at 10 o’clock or 2 o’clock position to avoid contact with the reflector.

5. Locate/assemble tubes w/o flange 2 and 3.

6. Tighten clamping bolts of both couplers. Tube weld seam facing down.

Torque coupling to 15-25 lbf ft (20-40 Nm)

Nut size 3/8 in



7. Mark out the position of the hanging brackets as shown in the assembly drawings section. The first hanging bracket to be 9 in (225 mm) from the burner mounting flange. Slide brackets over tubes. (9")(74")

8. Install the U bolts over the tubes into the holes in the bracket & loosely secure with nuts & washers. 8 x U-Bolt 3/8-16

Loose U-bolt 4 x Nut 3/8

Tight U-bolt 4 x Nut 3/8

Total: 22 x Nut 3/8 x 1 3/4

BURNER TUBE

RETURN TUBEU-BOLT TO BE LOOSENUTS AND WASHERS IN BOTH SIDES

U-BOLT TO BE TIGHTNUTS AND WASHERS ON BOTTOM ONLY

9. All the U-bolts on the firing tube except the U-bolt adjacent to the U bend should have nuts on both sides of the bracket to allow U-bolt to be tightened and allowing a 1/8" (3 mm) gap for expansion between the tube & U-bolt. Do not fully tighten at this stage.

10. Locate and insert baffles at the opposite ends of the tubes to the burner:

◊ 6 ft ( 183 cm) stainless steel on the 2nd tube

◊ 2 x 6 ft (183 cm) baffles on the 3rd tube

BAFFLE6 ft of stainless steel on the 2nd tube.

2 X 6 ft baffles on the 3rd tube.Lock both baffles together before inserting.

11. Install couplers between tubes and U-tube. When installing, orient band clamp lock bolts to top, at 10 o’clock or 2 o’clock position.



12. Lock both baffles together before insert. Place the baffle tabs at a 90° angle to the baffle keyhole. Insert baffle tabs in the keyhole. Rotate the baffle 90° to lock the baffle sections together.

13. Bend baffle tab over the end of the tube at the 6 o’clock position.

Reflectors Assembly

14. Install reflectors. Slide reflectors through the hanging brackets until they are all roughly in position along the heater. Referring to the assembly diagram locate reflectors 3 in (75 mm) from tube flanges and overlap by 4 in (100 mm)

15. Install the reflector seal with the flanges facing inwards (secure with screws to reflectors and U-tube reflector).

4 x Self-drilling screws #8-18-1/2 in



16. Install the U-tube reflector (overlap by 4 in (100 mm)), secure with screw to the reflectors and the reflector seal, 4 screws).


17. Install the U-tube.

18. Tighten clamping bolts of both couplers. When installing, orient band clamp lock bolts to top, at 10 o’clock or 2 o’clock position. Be sure not to over torque the coupling.

Torque coupling to 15-25 lbf-ft (20-40 Nm)

Nut size 3/8 in

Canopy and End Caps Assembly

19. Locate the reflector separators between the reflectors and canopy as shown in the Figure 12. Secure the separator to the return tube side reflector with 2 screws.




20. Locate and install the 1st canopy part. Slide the outer canopy over the reflectors from the U bend end ensuring correct location of reflector on the canopy flange. Maintain distance 1-2 in from the tube flange.

21. Locate and install the 2nd canopy part. Overlap the 2nd and 1st canopies by 4 in.

22. Locate and install the 3rd canopy part. Overlap the 3rd and 2nd canopies by 4 in

23. Secure the canopy parts together on top with two screws.


24. Install the U-tube reflector end cap (1 piece) with the flanges facing outwards (secure with 6 screw to U-tube reflector from inside).

6 x Self-drilling screws #8-18-1/2 in.

25. Install the canopy end cap (U-tube side) with the flanges facing inwards (secure with screw to canopy, 8 screws). Reflector end cap should be positioned inside the canopy end cap flange.




26. Install reflector end caps on the burner side (2 pieces) with the flanges facing outwards (secure with 6 screws to reflectors from inside).

2 x 6 x Self-drilling screws #8-18-1/2 in.

27. Install the canopy end cap (burner side) with the flanges facing inwards (secure canopy with screw, 8 screws). Reflector end caps should be positioned inside the canopy end cap flange.


28. Install one hex head self-drilling screw on the canopy, at the first hanging bracket on the burner box side, as shown in the graphic. The screw head will stop the hanging bracket moving during the heat up. Ensure that the screw will not touch the reflector.

1 x Self-drilling screws #8-18-1/2 in.A

29. Tighten all U-bolts on the cold side and only the U-bolt closest to the U-tube on the hot side.

30. Install the reflector connectors (3 pieces). Slide the connectors through the brackets until they are all roughly in position along the heater. 1

1

2

2

3

3

4

4

A A

B B

SIZE DWG NO REV

SCALE SHEET OF

DRAWNREVISIONS

No. APPD

CONCEPT 15_ASSEMBLY_CONNECTOR_22

1 1 0B

jwu 3/15/2016

DRAWING TITLEDETAIL

N.T.S.


± 0.1< 0.25

± 0.004

> 30to 120

± 0.3

± 0.012

> 0.25to 1

> 6to 30

± 0.2> 1to 5

± 0.008

> 120to 315

± 0.5> 5to 12± 0.02

> 12to 40

> 315to 1000

± 0.8

± 0.03

> 1000to 2000

± 1.2> 40to 80± 0.05

> 2000to 4000

± 2> 80to 160± 0.08

> 4000

± 3> 160

± 0.12inch

es


ECR#

milli

met

ers

DATE BY

M/D/Y


JW J.STARK.

angu

lar

1



NOTES

BOTTOM REFLECTOR COVERS

ASSEMBLED



31. Secure one of the bottom reflector cover closer to the U-turn on the reflector seal with a screw. Secure the middle bottom reflector cover on the first one. The third bottom reflector cover will be secured on the middle cover. Allow about 1 in (2.5 cm) between the cover edge and the canopy end cap flange.

3 x Self-drilling screw #8-18-1/2"

Burner Box and Heat Exchanger Installation

32. Install the burner box on the firing tube flange (gasket, 4 nuts and washers).

1

1

2

2

3

3

4

4

A A

B B

SIZE DWG NO REV

SCALE SHEET OF

DRAWNREVISIONS

No. APPD

CONCEPT 15_ASSEMBLY_INSTALL_HOUSINGS_25

1 1 0B

jwu 3/17/2016

DRAWING TITLEDETAIL

N.T.S.


± 0.1< 0.25

± 0.004

> 30to 120

± 0.3

± 0.012

> 0.25to 1

> 6to 30

± 0.2> 1to 5

± 0.008

> 120to 315

± 0.5> 5to 12± 0.02

> 12to 40

> 315to 1000

± 0.8

± 0.03

> 1000to 2000

± 1.2> 40to 80± 0.05

> 2000to 4000

± 2> 80to 160± 0.08

> 4000

± 3> 160

± 0.12inch

es


ECR#

milli

met

ers

DATE BY

M/D/Y


JW J.STARK.

angu

lar

1



NOTES

33. Install the heat exchanger on the cold tube flange (gasket, 4 nuts and washers).

34. Connect the heat exchanger outlet and blower inlet with flex connector (tighten the gear clamps).

35. Connect heat exchanger blower power cord and temperature switch to burner box connector.

36. Install the heat exchanger plastic flanged adaptor with condensate drain (gasket, four nuts and washers).

Gas and Vent Installation

37. Install the vent pipe. (Refer to venting section)

38. Install the siphon.

39. Connect gas supply fittings. (Refer to gas piping section).



INSTALLATION CHECKLISTNote: Complete checklist before lighting the heater. Correct any conditions that do not meet these instructions.

Heater Assembly F First hanging bracket 9 in (225 mm) from the burner mounting flange. F Radiant tube weld seam facing down F Baffles inserted at opposite ends of the tubes to the burner. Baffle tab bent over end of tube at 6 o’clock position.

F Tube couplings with the band clamp lock bolts oriented at the 10 o’clock or 2 o’clock position F Band clamps robustly tightened on the tube couplings F Reflector end cap (U-tube side) positioned inside the canopy end cap flange. F Reflector end caps (burner side) positioned inside the canopy end cap flange. F Canopy parts secure with two screws together on top.

Heater Location F Located indoors. F Installation area free of corrosive elements and flammable material. F Proper clearances from combustible surfaces maintained. F Sufficient room to service the heater. F Requirements for combustion air supply and dilution air for unvented heater F Heater installed with a slope downward and away from the burner of ¼ in (6 mm) in 10 ft (3 m). F All Quick links are tightened up and S hooks closed.

Gas Supply and Piping F Gas supply is as specified on the heater label. F Gas line equipped with shut-off valve, union and sediment trap. F Approved pipe joint compound used. F Adequate pipe size and of approved material. F Checked all connections and fittings for possible gas leaks.

Vent Pipe System F Material for vent pipe and fittings approved for sustained flue gases up to 230°F (110°C). F Approved size, length and number of elbows on exhaust vent and air intake system. F Installed in accordance with prevailing provisions of local codes, or in the absence of such, the latest edition of “National Fuel Gas Code”, ANSI Z223.1/NFPA 54 and CSA B149.1 Installation Codes in Canada

F Horizontal piping slopes at an upward pitch of 1/8in rise per 5 ft away from the heater. F Not obstructed in any way. F Provisions made to drain the vent condensate. F General rules for vent terminals F Away from corners, other vents, windows etc. F Exhaust and Air Intake terminations 18 in min. above roof/snow level.

Electrical Connections F Heater properly grounded. F Installed in accordance with prevailing provisions of local codes, or in the absence of such, the latest edition of “National Electrical Code” (NFPA 70)” and the Canadian Electric Code, CSA C22.1 in Canada, and must comply with all local requirements

After all actions on checklist are checked / completed - proceed with start up.


TROUBLESHOOTINGBurner Blower / Motor Fails To Run

• Is the thermostat calling for heat? Is there 115V at the burner receptacle?

• Check blower for obstructions. Replace blower if necessary.

• Pressure Switch (N.O.) Failed Closed. Replace as necessary.

• Check High Limit Switch (N.C.) for continuity.

Heat Exchanger Blower / Motor Fails To Run • Check heat exchanger blower power cord is connected to burner box cable connector.

• Check blower for obstructions. Replace blower if necessary.

The Ignition Module Fails to Energize the Igniter • Check air pressure switch performance with a manometer – Compare with switch setting.

• Ensure the correct size of exhaust and air intake pipes were used per the instruction manual for vent length. Ensure maximum number of elbows or equivalent feet of both pipes was not exceeded. Ensure there are no obstructions in the exhaust and air intake pipes.

• If the air pressure switch performance test results prove the air pressure switch is working properly, and all other steps are followed, and fault code persist – replace the control.

No Gas Supply • Check to see if manual supply valve to heater is ON (Open). No manifold pressure indicates valve is closed.

Gas pressure downstream of gas control can be measured by connecting a manometer to pressure tap on control. If the valve is closed, neither the gas valve knob on heater gas control is ON.

• Supply gas pressure can be checked at 1/8 in NPT pressure tap in gas supply system.

Burner Does Not Light • Is spark visible through site glass during ignition trial? If no, further electrical checks by a qualified service

person are required.

• Check to see if gas lines were properly purged of air.

• Check inlet and manifold gas pressure during ignition period.

• Check for proper orifice and air plate.

Burner Does Not Stay Lit • Check ground wire continuity.

• Check insulation on the igniter leads.

• Measure flame signal current; it should be between 2 to 6 micro amps DC. Minimum 0.8 micro amps

• Clean flame rod if necessary.

• Replace module if necessary.


Troubleshooting Chart

Turn up Thermostat

Burner Blower Start?

Check 120V powerverify at Motor.

Replace Blower if required

Unplug Motordoes Motor / Impeller

spin freely?Rectify as required

Replace Module if no power to Motor

Check ThermostatReplace if required

Heat Exchanger

Blower Start?

Check PowerConnector

Unplug Motordoes Motor / Impeller

spin freely?Rectify as required

Does the Electrode Spark?

Check Electrode Gap Set to 1/8"

Is Pressure Switch Closed?

Is High Limit Switch Open?

Check Ignition Wire Replace if damaged

Check Air Lines to Pressure Switch

Check Burner Systemfor obstruction

Check Heat Exchanger

Box Temperature

Check 24V at Switch.Rectify Transformer or

Wiring as Required

Burner Lights?

Does 24V occur at valve during Ignition Trial? Check wring.Rectify as required

Is valve in ON position? Replace Valve

Check Gas Pressure at Valve.

Rectify as required

Burner Stays Lit?

Verify Sense ElectrodeVerify GroundVerify Wiring

Rectify as required

Is there a flame signal to Module?

Min. 0.8 Micro Amps.

IF PROBLEM PERSISTS CONTACT YOUR MANUFACTURER REPRESENTATIVE

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes Yes

Yes Yes Yes

Yes

No

No

No

No

No

No No

TROUBLESHOOTING


REPLACEMENT PARTSITEM NO. PART NO. DESCRIPTION ITEM

NO. PART NO. DESCRIPTION

1 P-CE057 Indicator Light 11 P-CE010 Power Cord

2 P-CE266 Ignition Module 12 P-CE006 Ignition wire

3 P-CG057 Gas Valve 13 APH-CS122 Heat exchanger housing

4 P-CE058 Transformer 14 APFA-CE277 Blower (Heat exchanger)

5 FA-CE276 Blower (Burner Box) 15 APP-CE279 Temperature Limit switch

6 P-CE003 Flame Sensor Electrode 16 APV-CT122 Adaptor

7 P-CE002 Spark Electrode 17 APP-CE278 Cable, burner to exchanger

8 P-UG001P Burner Cup 18 APP-CE273/APP-CE274 Connector Female / Male

9 P-CH011 Sight Glass Assembly 19 APP-CH231 Flex hose

10 P-CE158 Air Switch 20 P-CH046 Gear Clamp

1104

11

5

8

7691232

16

15

18

1719

1314


WARRANTY

THE APEX SERIES WARRANTYThe manufacturer warrants to the original owner that the product will be free of defects in material and workmanship as described below.

Component

Burner and Controllers

Heat Exchanger

Aluminized Radiant Tubewith Post Purge

Warranty Period

3 Years

10 Years

10 Years

The Manufacturer’s obligation under this warranty is limited to repair or replacement, F.O.B. its facility, of the defective part. In the case of replacement parts, the warranty period shall be the longer of the original warranty or a period of 12 months from the date of purchase. In no event shall the Manufacturer be liable for incidental expense or consequential damages of any kind. This warranty does not cover any shipping, installation or other costs incurred in the repair or replacement of the product. No materials will be accepted for return without authorization. This warranty will not apply if in the judgment of the Manufacturer, the equipment has been improperly installed, unreasonably used, damaged or modified. This warranty will not apply to damage to the product when used in corrosive atmospheres and in particular atmospheres containing halogenated hydrocarbons. No person is authorized to assume for the Manufacturer any other warranty, obligation or liability. THE REMEDIES PROVIDED FOR IN THE ABOVE EXPRESS WARRANTIES ARE THE SOLE AND EXCLUSIVE REMEDIES. NO OTHER EXPRESS OR IMPLIED WARRANTIES ARE MADE INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE.

AX-LT199_02272017al

315 N Madison StreetFortville, IN 46040

317-577-0337800-874-3285

[email protected]

www.AdvancedRadiantSystems.com

the apex range - mtneri.com · 10 2 aph-ch046 gear clamp table 3: burner box and heat exchanger....

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