marvel val-co guide to infrared heating

7/30/2019 Marvel VAL-CO Guide to Infrared Heating

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Gas-Fired Infrared Heating for Poultry Houses

www.val-co.com


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All claims related to gas-red, low-intensity heating are predicated on the equipment being designed, installedmaintained and serviced properly by a qualied proessional.

Installation Code and Annual Inspections: All installation and service o VAL-COequipment must be perormed by a

contractor qualied in the installation and service o equipment sold and supplied by Val-Co and conorm to all require-ments set orth in the VAL-COmanuals and all applicable governmental authorities pertaining to the installation, serviceand operation o the equipment. To help acilitate optimum perormance and saety, Val-Co recommends that a qualiedcontractor conduct, at a minimum, annual inspections o your VAL-CO equipment and perorm service where necessary, using only replacement parts sold and supplied by Val-Co.

Further Inormation: Applications, engineering and detailed guidance on systems design, installation and equipmentperormance is available through VAL-CO representatives. Please contact us or any urther inormation you may re-quire, including the Installation, Operation and Service Manual.

These products are not or residential use.

This document is intended to assist licensed proessionals in the exercise o their proessional judgment.


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Gas-Fired, inFrared HeatinGFor PoultryaPPlications

This document is intended to assist licensed proessionals in the exercise o their proessional judgment. 1 o 35

PREFACE

Energy CostsEnergy costs continue to rise and can skyrocket at an unprecedented pace. Heating uel and electricity costs

are not immune rom these trends. As a result, worldwide demand or energy eicient equipment has grown.

Energy and Poultry House OperationSince prices or the nal product are set by the market, integrators and growers are continually evaluating and

implementing automated technologies to produce birds more eiciently. The management o poultry houses during theearly brooding stage o a chicks lie largely determines whether they will reach their ull potential. Every hour that a

chicks environment is less than optimum reduces growth rate and increases eed conversion. Costs to both the groweand the integrator can be high i the brooding environment does not ensure that birds get o to a good, healthy start. Yetheating and electricity costs are usually the largest expenses encountered by growers. As a result, utilization o eicienheating methods can aect the bottom line o both growers and integrators.

Gas-red, low-intensity inrared heating is commonly used in commercial and industrial applications (e.g.warehousing, manuacturing, vehicle maintenance acilities). In recent years, gas-red, low-intensity inrared heating hasgrown quickly in popularity over traditional heating systems in agricultural applications because energy savings o up to50% can be achieved. Momentum or this technology increases as energy costs rise and integrators and growers spreadthe word.

Many gas-red, low-intensity inrared heaters are listed with Canadian Standards Associations Internationa(CSA) in North America, Europe and Asia. For a product to appear on these lists, and thereore qualiy or the CSAclaims, the product must meet the standards or consumer saety, health and environmental requirements and in somecases, energy saving criteria. The American Society o Heating, Rerigeration and Air Conditioning Engineers (ASHRAEhas also acknowledged the uel saving characteristics o gas-red, low-intensity heating over conventional heating systems in the HVAC Applications ASHRAE Handbook (Chapter 15).

In the poultry industry, gas-red, low-intensity inrared heating is, to some, unamiliar or misunderstood. Thepurpose o this manual is to help acilitate better understanding o gas-red, low-Intensity inrared heating and to help acilitate proper design and layout in a poultry house application. Once applied and installed properly, correctly maintainedand utilized, integrators and growers can enjoy an improved growing environment and obtain signicant uel savings ovetraditional heating systems.


8/42This document is intended to assist licensed proessionals in the exercise o their proessional judgment.2 o 35

INFRARED HEATINGPART 1:

Inrared Heating: A New Concept?1.1Primitive people had only the sun to keep them warm beore they discovered re. Sun and re both give o

inrared heat energy. The suns inrared energy is beamed downward toward Earth. Fire sends heated air, combustiongases and smoke upward, but the heat elt rom re radiates in all directions, not just upward. Thus, the popular ideathat heat rises is not entirely true; in reality, inrared heat travels in all directions rom the sun or rom a re. Rather thansaying that heat rises, it's more accurate to say that warm air rises. This means that since inrared heat travels in alldirections, the popular idea o rising heat would apply only to heating systems which rely on air to convey warmth.

The sun is estimated to be 93 million miles (149 million kilometers) away rom the Earths surace, yet it can

heat the entire earth. This is the most signicant example o the eectiveness o inrared heating. While the principle isas old as the sun, the application or its use today may seem very dierent than the currently accepted means o heating.For those who have only been exposed to conventional methods o heating, the concept o inrared heating may openup a whole understanding o heat transer.

The Electromagnetic Spectrum1.2In the 1800's, an English astronomer named Sir William Herschel believed that the heat we eel rom the sun

is present in the visible spectrum. As he experimented with a prism to diuse light into its visible color components, hediscovered that violet and blue light carried the least heat. As he moved the thermometer through the spectrum o colorstoward the red color, the temperature on the thermometer rose. It was actually beyond the red spectrum that the highesttemperature was reached. This spectrum o longer wavelengths was named the inrared spectrum.

Electromagnetic Spectrum1

The sun gives o a wide variety o electromagnetic energy. The electromagnetic spectrum dierentiates allknown types o electromagnetic energy by measuring the wavelength o the energy. The wavelength is measured inmicrons (one million microns are equal to one meter). The shortest wavelengths in the visible light spectrum are violetand blue light. Then, as the wavelengths get longer, we see green, yellow, orange, and nally red. Those rays with wave-lengths longer than red are called inrared.

Inrared Spectrum1

1. Roberts-Gordon LLC (1994), Sir William Herschel Inrared Handbook, 1.4 pages 4-5 and 3.2.1 page 26.


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Types o Gas-Fired Inrared Heaters1.3Gas-Fired, inrared heaters are usually classied into two simple groups: high-intensity, inrared heaters and

low-intensity, inrared heaters.High-Intensity inrared heaters (also known as luminous, plaque, ceramic or pancake heaters) mix gas

and air behind a porous ceramic grid. The mixture o uel and air is pushed through the small holes in the ceramic gridand burned on the grid ace with an open fame, producing surace temperatures between 1600F (870C) and 1800F(980C) and an orange glow.Since high-intensity inrared heaters utilize an open fame, the products o combustion (i.e. carbon dioxide and watervapor) remain, reducing the oxygen and increasing the humidity in the house environment. Thus, more ventilation is

required to restore oxygen and remove water vapor rom the house. The extra ventilation also tends to cool the environment, requiring the heaters to cycle on more oten, raising heating costs. In addition, although high-intensity inraredheaters produce intense heat, they are generally compact in size and the heat rom the unit is localized in a small areaproducing a wide range o temperatures within the house. The intense heat and combustion products produced by high-intensity, inrared heaters can create a house environment that is diicult to manage. Gas-red, low-intensity inrared heaters mix gas and air and then burn it inside a heat exchanger tube. Heaexchanger tubes are usually made o aluminized steel. The heat exchanger tube surace temperatures o gas-red, lowintensity inrared heaters reach maximum temperatures generally between 900 F (480 C) and 1100 F (595 C).

Gas-red, low-intensity inrared heaters have a long heat exchanger tube which allows the heat to be spreadover a much larger area as compared to the more localized heat rom a high-intensity heater. In addition, the inraredenergy emitted rom a gas-red, low-intensity inrared heater has a lower requency and longer wavelength than high-intensity inrared heaters. This allows surrounding objects, such as concrete, animals, walls, etc. to more easily absorbthe heat.

Gas-Fired, Low-Intensity Inrared Heater

Unitary, gas-red, low-intensity inrared heaters are typically used in poultry house applications. Unitary, gas-

red, low-intensity inrared heaters have a single burner located at one end o the heat exchanger tube. The combustiontakes place at the burner end, and the products o combustion are exhausted or vented at the opposite end. As a resultone end o the heat exchanger tube is warmer and gives o more heat than the other end. Overlapping the heat patternshelps create a nice, even heat. I the heater is mounted correctly, the end-to-end heat dierence is minimized. The moscommon installations are straight tube heaters, but U-congurations are also available.

The heat exchanger tube is covered by an aluminum refector that serves two purposes. First, the design othe refector directs the inrared heat emitted rom the tube to a 90 downward radiation pattern. This allows the systemto evenly distribute the inrared energy over a foor area two times as wide as the system is high. For example, a systemhanging 10 11 (3 m 3.3 m) above the poultry house foor can evenly heat across a 21' (6.4 m) area. Second, theshape o the refector minimizes heated air, which surrounds the heat exchanger tube, rom escaping. Retaining theheated air helps keep the heat exchanger tube warmer, thus allowing it to more eectively emit inrared energy to theobjects below. (Dierent steel alloys and/or coatings on the heat exchanger tube have dierent emissivity, resulting indierent outputs).



Val-C0 oers heat-treated, aluminized tubing with its gas-red, low-intensity inrared heaters*. Heat-treatedaluminized steel tubing rates high on the emissivity scale and is preerred in poultry applications due to the corrosionresistant properties. Val-C0 oers .024 gauge aluminum refectors with its gas-red, low-intensity inrared heaters. Theshiny aluminum surace helps refect and direct inrared heat away rom the ceiling.

* On all models, the rst 10' (3 m) o tubing is ALUMI-THERM steel and the remaining tubing is heat treated aluminized steel.

Emissivity: Measurement o a materials ability to give o inrared energy.

Emissivity Scale

1

:Materials and emissivities generally available in the industry.Key: 1.00 = A perect emitter.

Material Emissivity @Temperature C / F (wavelength )Plain Steel 0.79 to 0.81 538 / 1000 (3.6)Aluminized Steel (Type 1) 0.20 to 0.50 538 / 1000 (3.6)Aluminized Steel (Heat Treated) 0.80 538 / 1000 (3.6)Porcelainized Steel 0.92 to 0.96 38 / 100 (9.3)Cast Iron 0.95 538 / 1000 (3.6)Stainless Steel (Type 304) 0.44 to 0.62 538 / 1000 (3.6)Stainless Steel (Type 430 Polished) 0.10 to 0.20 38 / 100 (9.2)Pyromark Paint 0.80 538 / 1000 (3.6)

Refectivity: Measurement o a materials ability to refect energy or light.

Refectivity Scale:Materials and refectivities generally available in the industry.Key: 1.00 = A perect refector.

Material RefectivityTin 0.94Chrome 0.92Aluminum (Mill nish) 0.91 to 0.95Aluminum (Polished) 0.91 to 0.95

Nickel 0.90Aluminized Steel (Type 1) 0.50 to 0.80Galvanized Steel 0.72Stainless Steel (Type 304) 0.48 to 0.66Stainless Steel (Type 430 Polished) 0.80 to 0.90

1. Roberts-Gordon LLC (1994), Sir William Herschel Inrared Handbook, 1.4 pages 4-5 and 3.2.1 page 26.


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Straight and U-tube gas-red, low-intensity inrared heaters in the same building.


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Air Heating with Warm Air Heaters2.2Growers consider the gas or oil red warm air heater to be a compact, stand alone, inexpensive and accept-

able method o heating. Warm air heaters certainly provide less uniorm heat than could be achieved with boiler systemsor other heating methods. They are oten placed at the end o the poultry house with the heated air directed toward themiddle o the house. Consequently, there tends to be an area in the middle o the house that is warmer than the sidesand ends. Since the an pushing air across the heat exchanger to the center o the house is drawing cold air rom behindand below, the foor at the end o the house is cooler.

Warm Air Heater

High-Intensity Inrared Heaters2.3High-intensity, inrared heaters use an open fame to combust a mix o gas and air on a porous ceramic or

metal grid, producing an orange glow. The combustion products are released directly into the house environment. Sincethe physical size o the heater is small, the heat elt rom the unit is localized in a small area and has higher intensity.These heaters are more appropriate or spot heating applications. However, the open fame, high oxygen consumption,localized intense heat and increased humidity make high-intensity inrared heaters diicult to manage in poultry househeating.

High-Intensity Inrared Heater


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Pancake Brooder Heaters2.4The pancake brooder type heater (also called gas radiators or jet brooders) is widely used in the United States

and other parts o the world. Pancake brooder heaters have an umbrella or pancake shape and are relatively small, asa result, heat output is very low. Consequently, more pancake heaters are required to uniormly heat a large space. Pancake brooders are oten located about 3' (1 m) above the foor and heat the foor beneath it somewhat uniormly. Theseheaters, generally, transer about 40% o their energy as inrared heat to the foor and 60% to the air as convective heatThis means that there will be some heat loss through the roo due to stratication. Since they are mounted at a low levelthey have to be raised or moved when the poultry house is loaded out. In addition, since pancake heaters involve anopen fame (like high-intensity inrared heaters). These types o heaters consume valuable amounts o oxygen and add

moisture to the house environment, requiring extra ventilation and can cause the heaters to cycle on more requently,resulting in increased energy costs.

Pancake Brooder Heater

Central Wet Systems (Boilers)2.5Wet systems are among the most expensive poultry house heating systems. Despite the cost, boiler systems

have gained widespread acceptance and popularity due to their multi-unctionality and good heat distribution. The pipesradiate heat in all directions. Convective heat also rises rom the pipes. However, much o the heat needed by the broodis directed upward and is transmitted through the roo o the poultry house. Wet systems are also particularly slow toadjust to outside climate changes.

Although boiler eiciencies have improved, this heating system still possesses high operating and mainte-nance costs that growers have come to accept. A single, large boiler correctly sized or the heat loss o a poultry houseat outdoor design temperature conditions, can be grossly oversized when temperatures are mild or ew zones are callingor heat. This oversized condition can lead to short cycling, which is inherently ineicient, but the use o staged boilersystems can reduce short cycling. In addition to prohibitive initial costs, growers must have a standby boiler in case themain one ails.

Central Wet System (Boilers)



Cabinet Heaters2.6Growers consider LPG gas or oil-red cabinet heaters to be a stand alone, acceptable method o heating.

Cabinet heaters certainly provide less uniorm heat than gas-red, low-intensity, inrared heaters. They are oten placedin a room separate to the main building to keep the units clean rom debris. The cabinet heater is then ducted into themain building and oten times, the exhaust fue gases are ducted in or extra heat. With air being orced into the space,there tends to be an area in the middle o the house that is warmer than the sides and ends. Louvers on the ducts canbe positioned to direct some o the heated air downward to try to reduce immediate heat stratication and cold spots.Typically, however, the ends o the house and the foor remain cooler, while the cost o the additional an adds to the costo electricity.

Example o a Cabinet Heater*

*All installation and service o VAL-CO equipment must be perormed by a contractor qualied in the installation and service o equipment soldand supplied by Val-Co and conorm to all requirements set orth in the VAL-CO manuals and all applicable governmental authorities pertainingto the installation, service and operation o the equipment. To help acilitate optimum perormance and saety, Val-Co recommends that a qualiedcontractor conduct, at a minimum, annual inspections o your VAL-CO equipment and perorm service where necessary, using only replacement

parts sold and supplied by Val-Co.Applications, engineering and detailed guidance on systems design, installation and equipment perormance is available throughVAL-CO representatives. Please contact us or any urther inormation you may require, including the Installation, Operation andService Manual.


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80F (26 C), with a ew warm spots accounting or the burner head placement. This slight range in temperatures allowsthe birds to move around to areas where they eel most comortable..

Floor temperatures ater 20 minutes o air heating. 2 *

Floor temperatures ater 10 minutes o high-intensity heating.

2

*

Floor temperatures ater 10 minutes o heating with gas-red, low-intensity inrared tube heaters.2 *

2. Czarick, M. (2005), Inrared Tube Heater Floor Heating Patterns, The University o GeorgiaCooperative Extension Service: Poultry Housing Tips, 17, 5, pp. 1-10

*Results may vary


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This poultry house relies on high-intensity heaters or heat. You can see the chicks are spaced out around the hot spots,conrming the test results ound regarding uneven foor temperatures with pancake brooder heaters, as shown on pages 11 and 12.



Easy Installation and Maintenance:3.2.3Gas-red, low-intensity, inrared tube heaters can be easy to install and service. Typically, no special equipment

is needed or the installation.* VAL-CO installation, operation and service manuals illustrate installation, control wiring,maintenance and repair considerations.

Gas-red, low-intensity, inrared tube heaters are mounted overhead so there is little intererence with ventila-tion airfow. Typically, there is also no need to adjust heater mounting height throughout the growing cycle. Gas-red,low-intensity, inrared tube heaters are mounted close to the ceiling, creating minimal obstruction o the chicken houseand improving the spread o inrared heat.

Unlike pancake brooder heating equipment, gas-red, low-intensity inrared heaters can remain in the house

during cleanout. Gas-red, low-intensity, inrared tube heaters are mounted near the ceiling and are well out o the wayduring house clean out and poultry removal.Gas-red, low-intensity, inrared tube heaters use resh air as combustion air. When heaters are properly in-

stalled and maintained in accordance with the installation, operation and service manual and applicable governmentregulations, the amount o contaminants that the internal components o the burner are exposed to is reduced. Thishelps result in years o trouble ree operation. Brooder heaters require more maintenance than gas-red, low-intensity in-rared tube heaters. Since they use air rom the house, pancake brooder heaters must be maintained ater every fock.

It is recommended that the refectors and tubes be cleaned periodically in order to continue to operate at op-timal eiciency. By comparison, it can be more eicient and cost eective to maintain ve or six gas-red, low-intensity,inrared tube heaters versus twenty to thirty pancake brooder heaters.

Gas-red, low-intensity, inrared heaters are overhead and out o the way or house cleaning.Environmental Benets - Warmer Floors and Drier Litter:3.2.4

Gas-red, low-intensity, inrared heat is directed to objects below the heater, including the foor where the birdsreside. In addition to creating a warm, comortable temperature or the birds, the litter on the foor absorbs the energyand is heated, evaporating moisture rom the litter. A drier litter improves the house environment by reducing ammoniageneration. Drier litter can also help lower mortality rates, as wet litter is an ideal breeding ground or many diseases andbacteria.

*All installation and service o VAL-CO equipment must be perormed by a contractor qualied in the installation and service o equipment soldand supplied by Val-Co and conorm to all requirements set orth in the VAL-CO manuals and all applicable governmental authorities pertainingto the installation, service and operation o the equipment. To help acilitate optimum perormance and saety, Val-Co recommends that a qualiedcontractor conduct, at a minimum, annual inspections o your VAL-CO equipment and perorm service where necessary, using only replacement

parts sold and supplied by Val-Co.Applications, engineering and detailed guidance on systems design, installation and equipment perormance is available throughVAL-CO representatives. Please contact us or any urther inormation you may require, including the Installation, Operation and

Service Manual.


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Environmental Benets Improved Poultry Production:3.2.5Comortable and consistent temperatures along eed and water lines, reduced moisture on the foor and bette

air quality all create a healthier environment to promote reduced mortality rates. The long, linear design o gas-red, low-intensity, inrared tube heaters create warm temperatures to invite birds along the length o water and eed lines.

Gas-red, low-intensity, inrared tube heaters do not blow warm air around the space. The heater emits inraredheat rom the heat exchanger tube without blowing air, dirt and dust, which can help acilitate better air quality.

The gentle warmth that is emitted rom the tube surace is refected and redirected toward the foor where theheat is needed or the comort o the birds. Plaque and pancake brooders produce convection heat and radiation heat inthe ollowing proportions: 60%-40%, thus 40% o the heat cant be directed toward the foor where it is needed.

Environmental Benets Save Valuable Oxygen:3.2.6

When connected to a fue and properly installed, used and serviced, gas-red, low-intensity inrared heaterstake resh air or combustion rom outside the house saving valuable oxygen. In contrast, unfued high-intensity heatersand warm air heaters can consume important volumes o oxygen rom inside the house. This can create condensationand humidity, resulting in water on the litter. This can be critical in poorly insulated or static houses.

Low-Intensity Inrared Heating vs. Air Heating (Gas and Oil Direct-Fired Warm Air Heaters)3.3Air heating systems usually cost less to install than a gas-red, low-intensity inrared heating system. However

these systems usually cost the grower considerably more to operate. Air heating systems are decient in two basic lawso heat transer. First, due to natural convection, warm air in the presence o cold air rises. Inrared energy does not risewhen properly directed to the foor.

Inrared heaters heat objects, not air, so stratication o air does not occur to nearly the same extent. The

refector over the system helps ensure that the energy is directed downward where it is most useul. Second, movingwarm air over objects (poultry) cools objects that contain moisture. Evaporation o water has a cooling eect. Properlydesigned, installed and used, gas-red, low-intensity inrared heating systems should provide a much more uniorm headistribution compared to air heating systems.

Low-Intensity Inrared Heating vs. Wet Systems3.4Steam and hot water boilers have been used or generations and have been accepted or heating

poultry houses. That view is changing, as growers realize boilers and piping systems are expensive to install. Separateequipment areas or buildings are required to house boilers, adding to construction costs and using valuable foor spaceOn the other hand, gas-red, low-intensity inrared heating systems do not take up foor space, and additional systemscan be added as additional poultry houses are built.

While eiciency is being improved, wet systems are still a long way rom being as uel eicient and eective as

gas-red, low-intensity inrared heating systems. The recommended maintenance schedule or boilers can be expensiveI a boiler is shut down or repair, there is no heat source or the poultry house unless a second expensive standby boilecan be put into operation. There is solid economic justication or replacing older boilers with new gas-red, low-intensityinrared heating systems, as the payback and return on investment can occur in just a ew years.

Low-Intensity Inrared Heating vs. Pancake Brooder Heaters3.5The pancake heater is relatively small and as a result, heat output is very low. Consequently, more pancake

heaters are required to uniormly heat a large space. Pancake brooders are located about 3' (1 m) above the foorBecause they are mounted at a low level, they have to be raised or moved when the poultry house is emptied andadjusted during fock cycles.

Gas-red, low-intensity inrared heaters, generally heat a larger area, so less heaters are required than broodeheaters. They are also mounted closer to the ceiling, so they do not need to be moved when the poultry house is emptied*.

Inrared Heating as the Energy-Saving Option o Choice3.6Many solutions to enhance energy savings have been oered to integrators and growers. As discussed earlier

these proposed energy-saving solutions commonly create other problems, which need more solutions, and so on. Withgas-red, low-intensity inrared heating, the energy-saving problem is solved with energy savings up to 50% over con-ventional heating systems. On top o energy savings, an objective grower must consider the additional intrinsic benetsthat may help enhance the growers prots. Low maintenance costs, improved poultry production, as well as an improvedhealthy environment, all add up to the overall protability o the poultry house.*All installation and service o VAL-CO equipment must be perormed by a contractor qualied in the installation and service o equipment soldand supplied by Val-Co and conorm to all requirements set orth in the VAL-CO manuals and all applicable governmental authorities pertainingto the installation, service and operation o the equipment. To help acilitate optimum perormance and saety, Val-Co recommends that a qualiedcontractor conduct, at a minimum, annual inspections o your VAL-CO equipment and perorm service where necessary, using only replacement

parts sold and supplied by Val-Co.Applications, engineering and detailed guidance on systems design, installation and equipment perormance is available throughVAL-CO representatives. Please contact us or any urther inormation you may require, including the Installation, Operation and

Service Manual.



TYPES OF GAS-FIRED, LOW-INTENSITY, INFRARED HEATERSPART 4:There are several models o gas-red, low-intensity, unitary, inrared heaters. The most commonly used or

poultry houses are:

ModulatingSingle-StageTwo-Stage

VAL-CO4.1 North American Products

Modulating Low-Intensity, Inrared Tube Heaters4.1.1Gas-red, low-intensity, modulating inrared tube heaters oer an enhanced control option. The heater is ca-

pable o operating not only at low and high re, but also at any input in between the high and low inputs. This improvedcontrol technology allows the heater to deliver the amount o heat needed to more precisely maintain temperatureswithout temperature overshoot. The precise control o the heater helps acilitate longer, more eicient run times andreduces ineicient heater cycling. In addition, through gas-air linkage technology, the heater is able to vary not only theuel supplied to the burner, but can also vary the combustion air supplied. This technology allows the heater to maintaineicient operation at various ring rates.

Fuel savings dierences between the several styles o tube heaters were measured by a large integrator inthree identical chicken houses on the same arm. The rst house used single stage (xed ring rate) tube heaters, thesecond house used two-stage (dual ring rate) tube heaters, and the third house used the new modulating tube heat-ers. In the study uel useage was as expected with the two-stage house being the least eicient, ollowed by the singlestage house, with the most uel eicient house using the modulating heaters. There was no signicant dierence in bird

perormance between these houses.

Study o uel use between modulating inrared heaters vs. two stage heaters.*

Benets o Modulating Gas-Fired, Low-Intensity, Inrared Tube HeatersHelp to provide more accurate control to meet heating demands by allowing even the slightest change in heater

ring rate anywhere within the 60-100% range.

Help to p rovide real energy savings by matching the heating systems input to the buildings heat load requirement.

The precise heater controls remember the last heating cycle, starting the new heating cycle at the optimum rate,resulting in longer heater run times, as opposed to requent heater cycling.

*Results may vary


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Single-Stage Gas-Fired, Low-Intensity, Inrared Tube Heaters4.1.2A standard gas-red, low-intensity inrared tube heater operates at a single input rate. For most poultry house

applications, the heater input is between 80,000 BTU/h (23kW) and 150,000 BTU/h (45 kW) depending on the lengtho the heater and mounting height. When there is a call or heat, the heater res at the rated input until the temperaturesetpoint is satised, then turns o until the next call or heat.

With single stage heaters, a blower pushes air and gas through the heat exchanger tube, expelling it outsidethe building at the end o the unit. These units have a single burner on one end o the heat exchanger tube. Growers alsond these systems to be very eective or heating brood sections and grow out sections. Positive pressure, unitary heaters may be installed so that the heat exchanger tube is laid out in one o a variety o shapes. The most common heate

installation is straight tube; U-shaped or L-congurations are also available.

VAL-CO Single Stage Gas-Fired, Low-Intensity, Inrared Tube Heater.

Twin-Fire Gas-Fired, Low-Intensity, Inrared Tube Heaters4.1.3A variation on the single-stage gas-red, low-intensity inrared tube heater is the twin-re (or twin-tube) design

The twin-re design operates at a single input, but each burner unit oers two inrared heat exchanger tubes and refectors that extend rom opposite sides o the burner unit.

Each side o the twin re heater operates at an input that is hal o the ull rated input o the heater. For instancei the rated input o a twin re heater is 250,000 BTU/h (70kW), each side o the heater operates at 125,000 BTU/h(35kW). The twin heat exchangers allow a single heater to heat twice the area o a tube heater with one heat exchangerthereore taking the place o two heaters. An advantage o the twin re design is that only one electr ical and gas connection are needed. This can result in lowering the gas piping and electrical installation costs.

Although not recommended or brooding sections o a house, a twin re heater can be successully employedin the grow out section o the house.

VAL-CO Twin Fire Gas-Fired, Low-Intensity, Inrared Tube Heater.



VAL-CO4.1.4 Gas-Fired, Low-intensity, Inrared Tube Heater Input Rates

VAL-COSingle Input Inrared Heater

Rated Input, btu/h (kW) Minimum Heat ExchangerLength t (m)

Maximum HeatExchanger Length

t (m)

80,000 (15) 20 (6) 30 (9)

100,000 (20 or 25) 30 (9) 40 (12)

125,000 (30, 35 or 40) 40 (12) 50 (15)

150,000 (45 or 50) 50 (15) 60 (18)

VAL-CO Modulating Inrared Heater(For North America Only)

Maximum RatedInput

Btu/h (kW)

Minimum RatedInput

Btu/h (kW)

Minimum HeatExchanger

Length t (m)

Maximum HeatExchanger Length

t (m)

80,000 (15) 48,000 20 (6) 30 (9)

115,000 (34) 75,000 (22) 30 (9) 40 (12)150,000 (44) 100,000 (29) 40 (12) 50 (15)

VAL-CO Twin-Fire Inrared Heater

(For North America Only)

Total Rated Input,Btu/h (kW)

Rated Input EachSide,

Btu/h (kW)

Minimum TotalHeat Exchanger

Length t (m)

Minimum HeatExchanger Length

Each Side t (m)

160,000 (47) 80,000 (23) 40 (12) 20 (6)

200,000 (59) 100,000 (29) 60 (18) 30 (9)

250,000 (73) 125,000 (37) 80 (24) 40 (12)300,000 (88) 150,000 (44) 100 (30) 50 (15)


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VAL-CO4.2 Wide Pattern HangersFor agricultural applications, Val-Co supplies a wide pattern hanger. The wide pattern hangers increase the

radiant spread by 24 compared to the normal hanger. This allows or a wider heat pattern or those extra wide poultryhouses. The wide pattern hanger can be hung at the normal 90 (level) angle or center mounting. This hanger does nohave a 45 angle (tilted) option. Val-Co supplies wide pattern hangers as standard with their heaters. I you preer regulahangers with a 45 option, please contact Val-Co.

Traditional pattern hangers radiant spread.

Wide pattern hangers increase radiant spread by 24 compared to traditional hangers oered by Roberts-Gordon.



DESIGN CONSIDERATIONS FOR POULTRY APPLICATIONSPART 5:

Typical Building Size and Shape5.1A typical poultry house can be 40'-50' (12 m-15 m) wide and 200'-500' eet (60 m-152 m) long. Wider houses

can be 66' (20 m) and beyond. The width o the house is a large determining actor in the planned layout o the heaters inthe building. Houses 40'-50' (12 m-15 m) wide can, generally, have a single row o heaters along the length o the house.This row is usually run down the center, but can also be mounted along a sidewall with the refector tilted 45 toward themiddle o the house. As broiler houses change in size, special considerations need to be taken to assure adequate heatis supplied throughout the building. As houses become wider (60' [18 m] and wider), it may be necessary to have tworows o heaters, unlike the most commonly used layout o one. Val-Co oers a wide range o BTUs, lengths and special

accessories that can be used to accomplish this.With the ever changing equipment that can be used in a broiler house, Val-Co oers several

accessories that can be used to protect components below and near the heat exchanger tube. Below is an example oa lower clearance shield and a side refector. These accessories can be used to protect drop cords, eed supply tubesand water lines i it is necessary.

Lower Clearance Shield

Side Refector


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The majority o poultry houses are single story buildings, but in some areas o North America, two story housesare common. Design layout parameters or these two-story buildings are typically the same as a single story applicationThe heater layout rom the rst foor would be repeated on the second foor. One o the benets o gas-red, low-intensityinrared heat is minimal stratication. The heat on the rst foor is absorbed by the fooring, litter, birds and other objectsinstead o rising into the second story space.

New poultry houses are being built wider to accommodate larger focks. As a select number o integratorschoose to utilize wider houses or increased foor space and larger focks, additional eed and water lines are usuallyrequired. The same consideration is applied to the heating equipment. Gas-red, low-intensity, inrared heaters oer a

wide variety o Btu/hour and tube lengths to accommodate these new broiler houses. Val-Co can assist in the designand layout o its heating equipment to insure adequate coverage and comort in these wider houses.

Gas-red, low-intensity heaters congured or large houses over 75.5' (23 m).


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Low Ceilings5.3Poultry houses, generally, have low roo proles and low peak heights. Inside the house there may not be open

access to mount the heater just below the peak i a drop ceiling is in place. Typically, the hanging height o the heaterin poultry houses will be between 9'-14' (2.75 m - 4.25 m) rom the foor, higher i space permits. Each heater has certied clearances to combustibles which must be adhered. The clearance between the top o the heater and the ceiling oceiling liner material must be maintained at all times or saety. This distance is less than 1' (0.3 m) and varies slightlydepending on model and input. Since some poultry houses have abric liners along the ceiling, care must be taken sothat liners above the heaters do not sag into a clearances to combustibles area. It may be necessary to put a protectiveshield above the rst length o tube to protect the ceiling rom high temperatures.

Open Ceiling House

Dropped Ceiling House

Building Use Throughout Brood Cycle / Dividers5.4It is common or poultry houses to be sectioned o so that the birds are contained in a small area (brood area

early in the grow cycle. As the birds grow, a secondary brooder area and grow-out area are opened up or the birds. Thisuse o the building should be considered during the heater layout design. Ideally, each heater will be entirely inside one

section or another and not located such that the partition is positioned across the heater. I a foor to ceiling partition islocated across the heaters, the partition must have a hole or the heater that is equal or greater in size than the heatersclearances to combustible area. Some partitions are just on the foor and wouldnt need to be cut. The clearances belowand to the sides o the heater are always greater than the clearances above the heater.



Temperature Sensor Location5.5Most growers preer to create a separate heat zone with each heater, so one sensor or thermostat is used with

every heater. The location o the sensor should be at bird level, or as close to the foor as practical. I there is one centralline o heaters, growers may initially locate the sensor somewhere between the outer water and eed lines and halwaybetween the burner and exhaust ends o the heater, to ensure adequate temperature and comort or the birds in thisarea.

Heat Sensor

Combustion Air Supply and Venting5.6Contaminants such as eathers, dust, water, etc., may collect on the ceramic surace o pancake heaters, low-

ering their eiciency. These heaters also cannot be vented, so combustion products are exhausted into the space andmix with the air the chickens breathe. With gas-red, low-intensity inrared heaters, corrosion resistant metal or fexibleduct is used to deliver outside air to the burner. Isolating the combustion air inlet rom indoor environment ensures thatcontaminants, which would shorten the heaters service lie, do not enter the burner. Gas-red, low-intensity inraredheaters have either 4" (10 cm) or 5" (13 cm) combustion air adapter diameter.

Most low-intensity, gas-red tube heaters are approved or vented or unvented operation, dependent upon localcodes and regulations. Unvented heaters require extra ventilation. Some heat will be lost due to extra ventilation.

Fresh Air Intake

Control Systems5.7


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It is common or poultry growers around the world to use a single control system or all equipment in the entirehouse. Many manuacturers oer whole house controllers to operate and monitor:

HeatingLightingNatural VentilationForced VentilationFeedingWatering

The majority o whole house controllers are capable o operating gas-red, low-intensity, inrared heaters

Some control systems used with high-intensity inrared heaters, fuctuate gas pressure through electro-valves. Systemsthat fuctuate gas pressure cannot be used with low-intensity, inrared tube heaters. However, poultry house controllermanuacturers sell all the accessories needed to control gas-red, low-intensity, inrared tube heaters. I a poultry housecontroller is not used, the heaters can be controlled by thermostat, or they can easily be tied into existing controls.



Typical Layouts or Various House Shapes and Sizes5.8The next ew pages show some widely used layouts in both the brooder and grow-out sections o broiler

houses. It is important to have the design and layout or all your agricultural buildings and houses perormed by a rep-resentative qualied in the design, installation and service o poultry equipment sold and supplied by Val-Co.

Types o Gas-Fired, Low-Intensity Inrared Heaters

Single Fire Unitary Heater

Layout 1*

66'

500'

250'

BROOD SECTION GROW-OUT SECTION

66'

250'

31' 4.5"31' 4.5"

31' 4.5" 31' 4.5"31' 4.5"31' 4.5"

31' 4.5" 31' 4.5"

55' 8" 55' 8"55' 8"

66'

250'

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

BROOD SECTION

GROW-OUT SECTION

*drawings not to scale


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Layout 2*

500'

250'

40'

30'

100 Btu/h x 1000

30'

100 Btu/h x 1000

30'

100 Btu/h x 1000

30'

100 Btu/h x 1000

30'

100 Btu/h x 1000

BROOD SECTION GROW-OUT SECTION

250'

40'16' 8"

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

16' 8" 16' 8" 16' 8"16' 8"

GROW-OUT SECTION

250'

40' 15' 5" 15' 5" 15' 5" 15' 5" 15' 5" 15' 5"

BROOD SECTION

Layout 3*

500'

250'

40'

16' 8" 16' 8"16' 8"16' 8"16' 8"

31' 4.5"31' 4.5" 31' 4.5" 31' 4.5"

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

BROOD SECTION

BROOD SECTION

GROW-OUT SECTION

GROW-OUT SECTION

250'

40'

250'

40'

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

Layout 4*




500'

250'

40'

16' 8" 16' 8"16' 8"16' 8"16' 8"

40'

100 Btu/h x 1000

BROOD SECTION

BROOD SECTION

GROW-OUT SECTION

250'

40'

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

16' 8" 16' 8"16' 8"16' 8"16' 8"

40'

100 Btu/h x 1000

GROW-OUT SECTION

250'

40'

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000

40'

100 Btu/h x 1000



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INSTALLATION TIPSPART 6:

Heat Coverage6.1The refector on a VAL-CO gas-red, low-intensity, inrared heater is designed to give a uniorm inrared pat-

tern across the poultry house. The proximity o burners in the house and the types o heat exchanger tubes control theuniormity o inrared heat lengthwise in the poultry house. The burner end o the rst heater should always ace an out-side wall. Factors such as width and height o the house also infuence uniormity. Where height and width are limitingactors, uniormity may vary.

Heat Load Calculations6.2

To be sure the poultry house is properly heated based on its location, dimensions and other attributes, theamount o heat required or a successul fock must be determined. This will help identiy the proper sizing and position-ing o low-intensity, gas-red tube heaters. In the U.S., integrators set the heat load based on the barn design, its ageand location. Integrators typically recommend 70 95 Btu/t2. However, i the barn has high inltration or poor insulationmore Btu/hr may be required. Conversely, a new barn with high R-value insulation and low inltration may need less. It isimportant to have the heat load calculation perormed by a proessional qualied in the design, installation and serviceo poultry equipment sold and supplied by Val-Co.

Clearances to Combustibles6.3When choosing a location or a heat exchanger tube, it is crucial to pay close attention to the area immediately

above, below and to each side o the tube. Consider the distance rom gas lines, house dividers, equipment suspensioncables and any possible sensitive material when determining how to meet the required clearances since objects tooclose to the heat exchanger tube may be damaged. While many objects can tolerate the inrared energy they receivenear the heat exchanger tube, a sae and comortable recommendation would be to keep objects at least a distanceequal to the clearances to combustibles rom the heat exchanger tube. The Installation, Operation and Service Manuaor specication sheet will give specic distances above, beside and below combustibles. Be sure to ollow these important specications.

Location o Other Structural Objects6.4

When designing and installing VAL-COgas-red, low-intensity, inrared heaters, it is important to avoid conficwith structural and mechanical eatures such as low ceilings, dividers, ventilating apparatus, watering and eed linesetc.

Heating Criteria6.5Gas-red, low-intensity, inrared heaters oer fexibility in design. Long, narrow poultry houses are a convenien

shape and easily solve the problem o providing uniorm heat. Growers generally preer to control temperatures to plus ominus 1 F (0.5 C) in 95% o the house production area. Commercial buildings are heated or creature comort. Poultryhouse heating is process heating, where the temperature o the poultry is an integral part o their growth.



MAINTENANCEPART 7:Each all beore the heating season gets underway, it is advisable to do a thorough inspection o the system.

Turn on the system and check to see that each burner lights. Have a contractor qualied in the installation o gas-redheating products check the fame to insure that is has proper color, and check the an. Check the outlet vent to makesure that the bird screen is in good condition.

Visual inspection o the outside air inlets is required or inrared heaters used in poultry houses. A simple dust-ing to keep refectors clean, allow them to continue eiciently directing the inrared rays toward the foor. Any mechanicalsystem will require care and maintenance to remain in peak operating condition. Because the inrared heaters are inplain sight overhead an owner can keep an eye on the general condition and operation o the system during the normal

daily routine.

Maintenance Checklist7.1Installation Code and Annual Inspections: All installation and service o VAL-CO equipment must be per-

ormed by a contractor qualied in the installation and service o equipment sold and supplied by Val-Co and conorm toall requirements set orth in the VAL-CO manuals and all applicable governmental authorities pertaining to the instal-lation, service and operation o the equipment. To help acilitate optimum perormance and saety, Val-Co recommendsthat a qualied contractor conduct, at a minimum, annual inspections o your VAL-CO equipment and perorm servicewhere necessary, using only replacement parts sold and supplied by Val-Co.

The Vicinity o the Heater Do not store or use fammable objects, liquids or vapors near the heater.Immediately remove these items i they are present.

Vehicles and Other Objects Maintain the clearances to combustibles.Do not hang anything rom, or place anything on, the heater.Make sure nothing is lodged underneath the refector, in betweenthe tubes or in the decorative or protective grilles (included with selectmodels). Immediately remove objects in violation o the clearances tocombustibles.

Refector Support refector with refector hanger and support strap.Refector must not touch tube.Make sure there is no dirt, sagging, cracking or distortion.Do not operate i there is sagging, cracking or distortion.Make sure refectors are correctly overlapped.Clean outside surace with a damp cloth.

Vent Pipe Venting must be intact. Using a fashlight, look or obstructions, cracks onthe pipe, gaps in the sealed areas or corrosion.The area must be ree o dirt and dust.Remove any carbon deposits or scale using a wire brush.

Outside Air Inlet Inlet must be intact. Look or obstructions, cracks on the pipe, gaps in thesealed areas or corrosion.The area must be ree o dirt and dust. Clean and reinstall as required.

Tubes Make sure there are no cracks.Make sure tubes are connected and suspended securely.Make sure there is no sagging, bending or distortion.Clean or replace as required.

Gas Line Check or gas leaks.

Burner Observation Window Make sure it is clean and ree o cracks or holes.Clean and replace as required.

Blower Scroll, Wheel and Motor Compressed air or a vacuum cleaner may be used to clean dust and dirt.

Burner Cup and Orice Clear o obstructions (even spider webs will cause problems).Careully remove any dust and debris rom the burner.

Electrode Replace i there are cracked ceramics, excessive carbon residue, orerosion o the electrode.The electrode gap should be 1/8 (3.2 mm).

Thermostat There should be no exposed wire or damage to the thermostat.

Suspension Points Make sure the heater is hanging securely. Look or signs o wear on thechain or ceiling.


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Decorative and Protective Grille(optional)

The grille must be securely attached. Check that the side refector exten-sions are installed correctly and secured in place i necessary. (Decorativegrille only.)Make sure shield is installed correctly and secured in place, i necessary.(Decorative grille only.)

Lower Clearance Shield (optional) The lower shield must be securely attached. Inspect shield support strapsand lower clearance shield anchor points.Make sure shield is installed correctly and secured in place, i necessary.

Wall Tag I wall tag is present, make sure it is legible and accurate. Please contactVal-C0 or your VAL-CO independentdistributor, i you need a wall tag.



APPLICATION PHOTOSPART 8:

Gas-Fired, Low-Intensity inrared heaters heating a poultry house in the United States.



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Gas-Fired, Low-Intensity inrared heaters heating a poultry house in the Middle East.

Gas-Fired, Low-Intensity inrared heaters heating a poultry house in Arica.



Gas-Fired, Low-Intensity inrared heaters heating a poultry house in Europe.



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Gas-red, low-intensity inrared heater being installed in a poultry house in Russia.

Gas-red, low-intensity inrared heaters heating a poultry house in Russia.


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Installation Code and Annual Inspections:All installation and service o VAL-CO equipment must be perormed by a contractor qualifed in the installation and

service o equipment sold and supplied by Val-Co and conorm to all requirements set orth in the VAL-CO manuals and all ap-

plicable governmental authorities pertaining to the installation, service and operation o the equipment. To help acilitate optimumperormance and saety, Val-Co recommends that a qualifed contractor conduct, at a minimum, annual inspections o your VAL-COequipment and perorm service where necessary, using only replacement parts sold and supplied by Val-Co.

Further Information: Applications, engineering and detailed guidance on systems design, installation and equipment perormance isavailable through VAL-CO representatives. Please contact us or any urther inormation you may require, including the

Installation, Operation and Service Manual.

These products are not for residential use.

This document is intended to assist licensed professionals in the exercise of their professional judgment.

VAL-CO.

210 E. Main Street

P.O. Box 117Coldwater, OH 45828 USA

Telephone: 800.998.2526Fax: 419.678.2200

www.val-co.com

marvel val-co guide to infrared heating

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