Ambirad VISION VSO Operating instructions

A

SSEMBLY

, I

NSTALLATION

& S

ERVICING

M

ANUAL

FOR

A MBI R AD V ISION

®

VSO & VSXO

R ANGE OF R ADIANT T UBE H EATERS

INDEX

Introduction and Document Index

Section

Commissioning Instructions ----------------------------------------------3

Servicing Instructions ------------------------------------------------------4

Spare Parts -------------------------------------------------------------------5

Fault Finding Guide --------------------------------------------------------6

Replacing Parts -------------------------------------------------------------7

User and Operating Instructions ----------------------------------------8

WARNINGS

AmbiRad equipment must be installed and maintained in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired products.

Due account should also be taken of any obligations arising from the Health and Safety at

Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896 (Industrial &

Commercial) and any other relevant British Standards and Codes of Practice by a qualified installer. All external wiring MUST comply with the current IEE wiring regulations.

1

2

Introduction.

Welcome to the new range of high efficiency

AmbiRad Vision radiant tube heaters. Local regulations may vary in the country of use and it is the installers responsibility to ensure that such regulations are satisfied.

All installation, assembly, commissioning and service procedures must be carried out by suitably qualified and competent persons to the statutory regulations in the country of use.

When assembling, installing, commissioning and servicing is undertaken on radiant tube heaters specified in these instructions, due care and attention is required to ensure that working at height regulations are adhered to at the mounting heights specified.

PLEASE READ this document prior to installation to familiarise yourself with the components and tools you require at the various stages of assembly.

All Dimensions shown are in mm unless otherwise stated.

The manufacturer reserves the right to alter

specifications without prior notice.

Document Index.

1 Installation Requirements

1.1 Health & Safety

1.2 Model Definitions

1.3 Heater Suspension

1.4 Wall Mounting

1.5 Herringbone Systems

1.6 Clearance to Combustibles

1.7 Gas Connection & Supply

1.8 Electrical Connections

1.9 Ventilation Requirements

1.9.1 Unflued Radiant Heater

Mechanical Ventilation

Natural Ventilation

1.9.2 Flued Radiant Heater

Mechanical Ventilation

Natural Ventilation

1.10 Flue & Combustion Air Inlet Options

1.10.1 Important Information

1.10.2 Flue Installation

1.10.3 Condensation Considerations

1.10.4 Flue/Tailpipe Connections

1.11 Technical Details

2 Assembly Instructions

2.1 Tools Required

2.2 Assembly Notes

2.2.1 Tubes

2.2.2 Turbulators

2.2.3 Brackets

2.2.4 Couplers

2.2.5 U Bend

2.2.6 Reflectors

2.2.7 End Caps

2.2.8 Burner Assembly

2.2.9 Heat Exchanger Assembly

2.2.10 HB Damper Assembly

2.2.11 Fan Assembly

2.2.12 End Moulding Fixing

2.2.13 HB Manifold Assembly

2.2.14 Detailed Assembly Drawings

3 Commissioning Instructions

3.1 Tools Required

3.2 Balancing the Herringbone System

3.3 Commissioning chart

4 Servicing Instructions

4.1 Tools Required

4.2 Burner Description

4.3 Burner Removal

4.4 Burner Gas Injector Servicing

4.5 Burner Head and Electrode Servicing

4.6 Combustion Fan Assembly Unitary Heater

4.7 Combustion Fan Assembly Powered Burner

4.8 Radiant Tube Servicing

4.9 Heat Exchanger Servicing

4.10 Reflector Servicing

4.11 Inspection of Flue

4.12 Re-commissioning after Service

5 Spare Parts

6 Fault Finding Guide

7 Replacing Parts

7.1 Burner Controller Replacement

7.2 Air Pressure Switch Replacement

7.3 Gas Valve Replacement

8 User and Operating Instructions

8.1 To Start Heater

8.2 To Switch Off Heater

8.3 Routine Maintenance Between Service Intervals

8.4 Frequency of Servicing

3

Isolate any electrical supply to the heater and controller before proceeding.

If there are any doubts as to the strength or suitability of roof steelwork to which heaters are to be suspended, please refer to a Consultant,

Architect or owner of the building. The

1.1 Health and Safety

minimum mounting heights for AmbiRad heaters are given in the table below.

AmbiRad heaters must be installed in accordance with the relevant provisions of the

Gas Safety (Installations and Use) Regulations

1998. Due account should also be taken of any obligations arising from the Health and Safety

Model

MINIMUM

Mounting Height (m)

Horizontal

Inclined / wall mounted

15 4.4 3.9 at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896

20

25

4.9 4.4

5.4 4.7

30 6.3 5.5 (Industrial & Commercial) and any other relevant British Standards and Codes of

Practice by a qualified installer. Isolate all electrical supplies to the heater & controller

35

40

6.5 5.7

6.9 6.0 before proceeding.

For your own safety we recommend the use of safety boots and leather faced gloves when handling sharp or heavy items. The use of protective eye wear is also recommended.

45

50

7.3 6.5

7.8 6.9

These radiant tube heaters can be wall mounted using the appropriate bracket (AmbiRad part no

WMB-13-22-38). aluminised steel reflectors, end caps, insulation, tube over shields, painted canopies and 35°. and optional end covers.

VSOUH = Vision U Tube Table 1 Angle Mounting

Herringbone heater with painted induced burner, Damper, aluminised steel reflectors,

U end caps, insulation, tube over shields, painted canopies and optional end covers.

VSXO = AmbiRad Vision High efficiency

U Tube heater with forced burner, recuperative

Heater

Size

15 - 50

Required angle

30-35°

Chain length

12 links

Eyebolt position

1 heat exchanger, aluminised steel reflectors, end caps, insulation, tube over shields, painted canopies and optional end covers.

Figure 1.a. Angle Mounting using the Wall mounting bracket

The heater must be suspended by

ALL of the suspension brackets.

See fig 1.b. Attachment to the heater support lugs should be made by a ‘speed link’, D shackle or in the case of drop rods, a closed formed hook. The hanging attachments to overhead steelwork etc. must be purpose made to good sound engineering practice or of a proprietary type fixing. They must be adequately fixed and designed to carry the whole weight of the heater. In the event of suitable roof steelwork being unavailable, additional steelwork should be fitted to enable vertical hangers to be used for suspending the heaters. 4

E

Figure 1.b. Recommended Methods of Heater Suspension.

*

*

5

1.5 Herringbone Systems (VSOUH).

The manifold system should be arranged to fall slightly in the direction of the vacuum fan. This ensures that any condensation formed in the manifold on cold start and cool down is not trapped or allowed to drain back into the heater unit. This allows condensate to flow towards the condensate trap located at the vacuum fan

‘U’ trap shall be 457mm deep. The end cap of the collecting chamber to be fitted with a flush flanged tank connector. Any protrusion to be removed leaving the inside flush with end cap.

end of the manifold system. (See figure 2a below for condensate trap arrangement).

The manifold should be supported by chain, stainless steel flexible wire, or other flexible means from the roof structure to allow movement caused by thermal expansion. For

100mm diameter manifold the maximum distance between supports is 2.4m and 3.0m for 150mm diameter .

Figure 2b. Collecting Chamber Arrangement

Flexible couplers (supplied by AmbiRad) must be inserted within the manifold system to allow linear expansion to take place and prevent stress and strain on the system.

The end cap should be sealed with silicon jointing compound and pop riveted in position.

All condensate drains from the flue collecting chamber to the disposal point shall be corrosion-resistant material of not less than

The manifold must be supported either side of the flexible coupler.

22mm internal diameter. Copper or copper based alloy shall not be used for condensation drains. See reference BS 6896. Condensate

The exhaust flue should be adequately drain pipes must be protected against the supported from the building structure and effects of freezing. installed in accordance with the British

Standard Code of Practice BS 5440 Part 1 –

The Type ‘0’ and Type ‘2’ vacuum fans have

Installation and maintenance of flues and bottom horizontal discharge with rectangular ventilation for gas appliances of rated input not connections (flanged on the type 0) and must be exceeding 70kW net (1st, 2nd and 3rd family mounted in that position by means of the fan gases) support stool onto a suitable platform or brackets fixed to the building structure.

A condensate trap assembly must be provided at the end of the manifold system before the

For details of the fan outlet fixing holes see hot gas vacuum fan. below.

Figure 2c. Type ‘O’ Fan Outlet Dimensions

Figure 2a.

Condensate

Trap Arrangement

Figure 2d.

Type 2 Fan

Outlet Dimensions

The minimum depth of the condensate collecting chamber shall be 305mm and the minimum depth of the condensate drain pipe

6

For details of fan mounting bracket and fixing down holes see figure 3.

Figure 2e. Conventional Flue Arrangement

Roof Exit.

Figure 2g. Stainless Steel Telescopic

Through The Wall Arrangement (available for

Type ‘O’ and Type ‘2’ fans)

Where a conventional flue is to be installed,

AmbiRad supply an aluminium transformation piece to which a 150mm (6ins) diameter flue must be attached.

The length of flue which may be connected to the fan outlet must be adequately supported from the building structure.

Figure 2f. Conventional Flue Arrangement

Wall Exit.

Figure 2h. Typical Low Fan Arrangement

7

Figure 3. Vacuum Fan Mounting Details (Type ‘O’ fan illustrated)

Hole Centers

Fan

E

F

G

H

A

B

C

D

J

K

L

Power (watts)

Running Current (amps)

Starting Current (amps)

Voltage

Fig 2c/d

Type O

340

332

363

550

2.6

15.4

230V 1ph

209

153

42

239

124

38

175

7.1

8

Hole Centers

Type 2

210

205

215

120

0.8

4.0

230V 1ph

125

100

25

120

80

35

174

7

Figure 4. Typical Herringbone system (VSO shown with optional end covers)

Dos and don'ts of herringbone system

Dos

Check design pressure drop.

Don’ts

Run drains in copper or mild steel pipework. proposed building - e.g. cleaning, electroplating, printers using sugar powder etc.

AmbiRad if the system will operate correctly.

Drain all flue ducts and seal all joints. Install flue with vertical rise without firstly fitting a drain point at it’s lowest level.

Secure joints with pop rivets as well as sealing compound (refer to assembly instructions).

Fit fan with outlet vertical or with top horizontal discharge.

Fit drain traps before and after fans (see figs 2). Fit damper upside down or on it’s side. intermediate points on the herringbone system.

Run drains in galvanised steel or plastic pipes.

Follow guide to combined flue heating system.

9

1.6 Clearance to Combustibles.

The minimum clearances to combustible materials are given in the tables below. These minimum distances MUST be adhered to at all times.

Figure 5.a Diagram illustrating the clearance to combustibles (VSXO shown c/w End Covers)

B

A

F

D

C

E

DIM 'C'

DIM 'C'

VSXO

Above Canopy

Above Burner / Flued Heat Exchanger

Above Burner / Heater Outlet Unflued

To the Sides

Below Tubes

From Heater Outlet (UNFLUED)

End Wall

A

B

B1

C

D

E

F

10

20/25 30/35/40 45/50

100 100 100

500 500 500

700 700 700

915 1200 1525

2330 2330 2330

570 940 940

390 470 575

Figure 5.b Clearance to combustibles Vision Optima Unitary VSO UT

F A

D

C

B

DIM 'C'

DIM 'C'

VSO UT

Above Canopy



To the Sides

Below Tubes


End Wall

A

B

B1

C

D

E

F

15/20/25 30/35/40 45/50

100 100 100

500 500 500

700 700 700

915 1200 1525

2330 2330 2330

570 940 940

390 470 575

11

Figure 5.c Clearance to combustibles Vision Optima Herringbone VSO UH

F A

D

C

B

DIM 'C'

DIM 'C'

VSO UH Herringbone

Above Canopy



To the Sides

Below Tubes


End Wall

A

B

B1

C

D

E

F

15/20/25 30/35/40 45/50

100 100 100

500 500 500

700 700 700

915 1200 1525

2330 2330 2330

570 940 940

390 470 575

12

1.7 Gas Connection and Supply

to the heater not to apply excessive turning force to the internal controls.

Before installation, check that the local distribution conditions, nature of gas appliance are compatible.

A flexible hose is installed to allow safe linear and pressure, and adjustment of the expansion of the heater without creating undue stress on the gas supply pipe work. It is therefore important that a tested and certified

A competent or qualified engineer is required to hose assembly made to ISO 10380, supplied either install a new gas meter to the service accordance with BS 6896, so that the supply with ½” BSP female cone seat adapters, is pipe or to check that the existing meter is adequate to deal with the rate of gas supply required. Installation pipes should be fitted in installed as per these instructions.

It is also important to ensure that expansion is taken up in the body of the flexible hose, and pressure, as stated in Table 4 will be achieved. not on its attachment to the pipe work. The cone

It is the responsibility of the competent engineer seat adapter supplied on one end of the flexible to ensure that other relevant Standards and gas hose provides a `swivel` action, and must

Codes of Practice are complied with in the be fitted on the burner using a ½” BSP barrel country of installation. Pipes of smaller size nipple to provide ease of disconnection for than the heater inlet gas connection must not future servicing. This assumes that the heater be used. The complete installation must be and fixed gas supply to the isolating valve have tested for soundness as described in the been installed. country of installation.

The installation layout described below is

The gas union service cock MUST be fitted in the gas supply close to the heater, but not onto the burner itself.

Take care when making a gas connection the only method recommended by the institute of gas engineers, the hose manufacturer, and AmbiRad and must only be carried out by a qualified/competent gas engineer.

Figure 6. Correct Installation of Flexible Gas Connection fig.a fig.b x

50 +/- 20mm fig.c x fig.d

300 +/- 50mm fig.e

Arrow denotes direction of expansion. fig.f

The methods shown in fig.e and fig.f are unacceptable, due to undue stress on the hose & fittings.

13

Depending on the specific installation, the flexible gas hose may be routed to the gas cock at any of the following angles in relation to the burner:

Vertical (fig.a)

45° angle (fig.b)

90° angle (fig.c)

Any other position in between these angles is acceptable.

A clearance distance ‘x’ of min 200mm must be observed to allow side door access .

Care must be taken to observe the minimum pipe bend diameter (minimum 250mm, maximum 350mm) & pipe expansion distance

(minimum 30mm, maximum 70mm) as shown in fig.d.

Maximum bend diameter for the 1000mm hose is 450mm.

The correct installation as shown will allow for approx 100mm of movement due to expansion.

Table 4 Gas Supply Pressures

Gas Category

Gas Type

Max Supply Pressure (mbar)

Min Supply Pressure (mbar)

Nominal Pressure (mbar)

Gas Supply

I2H

Natural Gas (G20)

25

17

I3P

Propane (G31)

45

25

20 37

Connection R½ ½in BSP Internal Thread

This appliance must be earthed.

Supply 230V 50Hz single phase.

Standard heater 116W.

Current rating 0.55 amp max (inductive).

Fuse: external 3 amp.

All electrical work should be carried out to IEE standards by a competent electrician. The electrical connection to the heater is made by means of a three pin plug-in power connector.

Live, neutral and earth connections should be made via a flexible supply cable to the power connector and routed clear of the heater or tubes.

The flexible supply cables should be of 0.5mm² and comply with BS 6500. The wires in the mains lead are coloured in accordance with the following code:

Green & Yellow Earth;

Blue Neutral;

Brown Live

14

It is recommended the heater or group of heaters are controlled by thermostats, a time switch and if required manual control switches and a frost thermostat.

We recommend use of AmbiRad approved

controls. Please refer to control manual for siting and installation details.

Where alternative manufactures controls are used, please refer to their instructions for their siting and installation details.

Figure 7.a Single Phase Wiring

Figure 7.b Typical VSOUT Induced Unitary Wiring Connections (end covers not shown)

Fused Spur

Fan plugs into burner

Figure 7.c Typical VSOUH Herringbone Wiring Connections (end covers not shown)

Fused Spur

Figure 7.d Typical VSXO Powered Burner Unitary Wiring Connections (end covers not shown)

Fused Spur


Figure 7.e Typical VSXO Powered burner Wiring Connections (end covers shown)

Fused

Spur


Figure 10. Internal Burner Wiring Diagram.

15

Figure 8. Internal Burner Wiring Diagram.

GREY

C.

N.O.

VACUUM

SWITCH

N.C.

SOLENOID VALVE

VALVE

J.S.T.

1 2 3

GRN/YLW

BLUE

BLUE

N

L

FAN

GREEN/YELLOW

EMC FILTER

MAINS INPUT

L N

BURNER

ON

MAINS

ON

LAMPS

BLUE

BROWN

BROWN

WHITE

MAIN J.S.T.

9

1 2 3 4

7 8

10 11 12

PINK

YELLOW

GREY

16

Figure 9. Typical VSO UH

Schematic Wiring

Connections

1 phase 230V

Exhaust Fan

Isolator

Tail Pipe

Isolator

Isolator

0.75mm²

Screened Cable

Sensor

Zone A

Isolator

Isolator

Controller

230V 50Hz 13A

Mains Supply

1.9 Ventilation Requirements

AmbiRad tube heaters can be operated as flued or unflued appliances in accordance with

Natural Ventilation

BS EN 13410 should be used to size air vents to provide adequate ventilation, an example of this calculation is given below: the relevant national requirements in the country of installation.

1.9.1 Unflued Radiant Heater

Radiant tube heaters can be operated as unflued appliances so that the concentration of

Carbon Dioxide (CO

2

) at positions where the air will be inhaled does not exceed 0.28%. BS EN

13410 is a guide to achieving this requirement.

If the building air change rate exceeds 1.5 per

Site Details:

20°c Internal Operating Temperature

0°c Outside Air Temperature

5m between high and low level vents

Following the sizing procedure in BS EN 13410 gives an air exit velocity of 1.6m/s. This equates to a free area vent at both high level and low level of 17.36cm²/kW free area.

1.9.2 Flued Radiant Heater hour or if the heat input is less than 5W/m³, no additional ventilation is required.

In addition to the ventilation requirements,

In buildings having an air change rate of less than 0.5 per hour, additional mechanical or natural ventilation is required. For detailed possibility of condensation forming on cold surfaces.

It should be noted that the clearance distance around the burner increases when the unit is operated unflued (see section 1.6). It should be ensured that the combustion gases do not impinge on any combustible materials.

Mechanical Ventilation

Mechanical ventilation must be rated at minimum 10m³/h per kW input using appropriately sized fans and interlocked with heaters.

5.2.2.2.1

Mechanical Ventilation

Mechanical ventilation must be installed to meet a minimum of 0.5 air changes per hour using appropriately sized fans and interlocked with the heaters.

Natural Ventilation

Low level ventilation openings with a free area of at least 2cm²/kW shall be provided. See section 5.2.2.2.2.1.

17

1.10 Flue and Combustion Air Inlet -

Options

Dependent on the type of burner fitted to your heater it is possible to have configurations of flue and combustion air inlet options to those shown overleaf:

• Option 1

For induced burner with / without flue and / or optional ducted air inlet refer to Figure 10.a

• Option 2

For herringbone heaters refer to Figure 10.b

& section 1.5 Herringbone Systems (UH/LH).

• Option 3

For forced burner with / without flue and ducted air inlet refer to 10.c

• Option 4

For ducted air and products of combustion to ventilated area please refer to Figure 10.c. &

10.d.

• Option 5

For flued products of combustion and ducted air via concentric pipe please refer to Figure

10.e.

1.10.1 Important Information

Flue systems can run either vertically or horizontally up to a maximum length of 9.0m

(including up to 2 x 90° bends plus the terminal).

The minimum flue length shall be 1m.

The flue system may be terminated vertically

or horizontally but in accordance with the

British Standard Code of Practice BS 5440: Part

1 - Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net (1st, 2nd and 3rd family gases), and the flue system manufacturers instructions as supplied with the flue.

1.10.1.3 Option 5

A suitable flue system complying with EN1865-1

(type T200 P1 W V2 L50050 O00) should be used.

Flue size 100mm diameter single wall.

The maximum flue length shall be 9.0m


The minimum flue length shall be 1m.

The flue system must be terminated vertically

only and in accordance with the British

Standard Code of Practice BS 5440: Part 1 -

Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70kW net (1st, 2nd and 3rd family gases), and the flue system manufacturers instructions as supplied with the flue.

1.10.1.1 Option 1 and 3

A suitable flue system complying with EN1856-1

(type T250 N1 D Vm L11040 O50) should be used.

Flue size 125mm diameter twin wall.

Flue systems can run either vertically or horizontally up to a maximum length of 9.5m


Connection to an appliance which is not

The minimum flue length shall be 1m. connected to the fuel supply may be carried out by a competent person. However, connection to

The flue system must be terminated in a an appliance that is connected to the fuel supply

vertical position and in accordance with the

must be carried out by a registered installer.

British Standard Code of Practice BS 5440: Part

1 - Installation and maintenance of flues and

If the flue passes through a wall, ceiling, or roof ventilation for gas appliances of rated input not made from combustible material then it has to exceeding 70kW net (1st, 2nd and 3rd family be sleeved so as to provide a minimum of a gases), and the flue system manufacturers

50mm void between the exterior of the flue and instructions as supplied with the flue. the internal wall of the sleeve. A minimum of

50mm must be maintained as a clearance

1.10.1.2 Option 2 distance to all other combustible materials.

The tailpipe as supplied by the manufacturer is to be used and installed as per the manufacturers design drawing. stainless steel flexible wire, or other flexible

A suitable flue system complying with EN1856-1 means from the roof structure to allow

(type T250 N1 D Vm L11040 O50) may be used movement caused by thermal expansion. as an alternative to that offered by the manufacturer.

18

The maximum distance between supports is

1.5m for horizontal runs.

Wall bands are not load bearing and give lateral support only. If used, wall bands should be fitted every 3m on vertical runs to ensure the system is rigidly held. The system should be braced immediately below passing through the roof line to ensure the flashing does not suffer lateral pressures.

The maximum height unsupported above the with the visible male collar pointing upwards, this is reaffirmed by the directional arrow pointing upwards, indicating the directional flow of flue gases. Taping of the joints is unnecessary.

1.10.4.2 Option 2 Tailpipe

After allowing for a minimum of 75mm (3in) of penetration of the fitting into the tube, cut the tubes to the lengths required and remove all burrs and wipe off any grease or oil with a clean roof line is 1.5m. Where a joint is above the roofline it should be determined that in extreme rag. wind conditions this joint would not be over The components are joined by pushing the male exerted. If there is any doubt then a guy wire spigot and female socket together until the stop should be used. Beyond this guy wires should be installed every meter.

The POCED is capable of withstanding its own is reached.

To seal use an applicator gun and apply a 4mm diameter bead of high temperature silicon weight when installed in accordance with these instructions and the Regulations shown below. jointing compound externally round the end of the male spigot and internally round the end of the female socket.

The exhaust flue should be adequately supported from the building structure and Push the male spigot into the female socket

Standard Code of Practice BS 5440: Part 1 –

Installation and maintenance of flues and jointing compound uniformly until a penetration of 75mm (3in) is achieved. ventilation for gas appliances of rated input not exceeding 70kW net (1st, 2nd and 3rd family Note The silicon jointing compound remains gases), and the flue system manufacturers instructions as supplied with the flue. See reference BS 6896. Condensate drain pipes workable after application for only 5 minutes

Secure the joint by drilling through the tube and must be protected against the effects of fitting and fix with three pop rivets at 12 o’clock, freezing. 4 o’clock and 8 o’clock positions. 4.8mm

(3/16in) diameter pop rivets are recommended.

1.10.3 Condensation

1.10.4.3 Option 5

When designing the flue system the prevention

The components are joined by pushing the male of the formation and entrapment of condensation must be a key consideration. is reached. No sealant is required, but can be applied if the formation of condensation is anticipated.

Horizontal flue should be fitted ensuring a slight gradient approx 5

° towards the terminal. Where condensation is unavoidable traps should be

To seal use an applicator gun and apply a 4mm included to encourage the condensates to flow diameter bead of high temperature silicon freely to a point from which they may be jointing compound externally round the end of released, preferably into a gully. The condensate pipe from the flue to the disposal the female socket. point must be made from corrosion resistant pipe of not less than 25mm internal diameter.

Push the male spigot into the female socket using a slight rotating movement to spread the jointing compound uniformly until both fittings

1.10.4 Method of Jointing Tube

have fully engaged.

1.10.4.1 Option 1 and 3

Note The silicon jointing compound remains components are joined together by a twist lock, bayonet system. The system should be installed

19

Option 1 - Figure 10a. Air Inlet Attachments Unitary Herringbone Burners (VSO)

B and rotate fan outlet to the HORIZONTAL

B and rotate fan outlet to the HORIZONTAL

position away from the burner.

Ducted Air Intake

Products of Combustion

D

E

A

B

C

Firing tube

Products of combustion

A 127mm (5ins) Twin Wall Flue System

Ventilation requirements are as detailed in section 1.9 or 7176-SUB (2506 fan)

Ducted air must be used in locations where there is airborne dust or where

D Optional Ducted Air Intake. VSI-DA

E Standard Air Intake (supplied as standard) there is a polluted atmosphere e.g.

Chlorinated Vapours.

Maximum length = 9m

Minimum diameter = 100mm

Maximum no of bends = 2

Maximum flue run = 9.5m @ Ø125mm


All flues must terminate vertically.

For further information on flue runs, please refer to section 1.10.1 and BS 5440 pt.1

20

Option 2 - Figure 10b. Air Inlet Attachments Induced Herringbone Burners (VSO)

Ducted Air Intake

C

B

A D

Firing tube

Products of Combustion

Ventilation requirements are as detailed in section 1.9

Ducted air must be used in locations where there is airborne dust or where there is a polluted atmosphere e.g. Chlorinated

Vapours.

Maximum length = 9m



21

B Air Intake (supplied as standard)

C Optional Ducted Air Intake. (see notes)

Option 3 - Figure 10c. Forced Burner with Heat Exchanger (VSXO Standard Flue)

For flued products of combustion and no ducted air


J

E

G

Air

Inlet

G

H

G

L

K

Firing

tube


F

Maximum flue length = 9.5m @ Ø125mm





Vapours.

Maximum length = 9m



22

G 100mm (4ins) Clips x2

H 100mm (4ins) Flexible Flue

J 100mm (4ins) Flexible Flue to Fan

K 127mm (5ins) to 100mm (4ins) Reducer

L 127mm (5ins) Twin Wall Flue Pipe


Option 4 - Figure 10d. Forced Burner with Heat Exchanger (VSXO No External Flue)

For ducted air and products of combustion to ventilated area

J

G

Fresh

Air

M

Products of combustion to

ventilated area

E

G

H

G

Firing

tube

F

Products of

combustion



Vapours.

Maximum length = 9m






M Shroud for unflued heater installation

(supplied as standard)

23

Option 5 - Figure 10e. Forced Burner with Heat Exchanger (with Concentric Flue)

For flued products of combustion and ducted air via concentric pipe.

Products of

combustion

IMPORTANT NOTE

This option is a type B

23

flue system with ducted air and is not a room sealed balanced flue product.

Fresh

Air

Inlet

E

G

J

G

P

Fresh

Air

Firing

Tube

Products of

combustion




N Flue Extension optional

(0.25m/0.5m/1.0m)

P Concentric Flue Terminal

Products of

combustion

N

H

G

F


Maximum flue length = 9.0m @ Ø125mm




24


Vapours.

Maximum length = 9m



1.11 Technical Details.

No of Injectors

Gas Connection

Flue Nominal Bore mm (in)

Unitary Fan Motor Details

1

½ in BSP Internal thread

125 (5)

230 volt 1 phase 50Hz

Table 5. Burner Settings - Natural Gas (G20)

Heater

Model

VSXO20UT

VSXO25UT

VSXO30UT

VSXO35UT

VSXO40UT

VSXO45UT

VSXO50UT

Heat Input kW

Gross Nett

Gas

Flowrate

(m³/hr)

Injector

Pressure

(mbar)

Injector

Size

(mm)

20.0 18.0 1.9

*Size

(h x l x w)

9.2 7 x 1.7 445x4120x826

*Weight

(Kg)

Fan

Rating

(A)

Fan

Type

104 1.0 2507

25.0 22.5 2.4 10.0 7 x 1.9 445x4120x826 104 1.0 2507

32.0 28.8 3.1 11.5 7 x 2.1 445x5955x826

36.0 32.4 3.5 11.5 7 x 2.3 445x5955x826

40.0 36.0 3.8 11.0 7 x 2.7 445x5955x826

44.0 39.6 4.2 11.6 7 x 2.9 445x7760x826

48.0 43.2 4.6 12.8 7 x 2.5L 445x7760x826

142

142

142

182

182

1.0 2507

0.5 2560

0.5 2560

0.5 2560

0.5 2560

VSO15UT

VSO20UT

VSO25UT

VSO30UT

VSO35UT

VSO40UT

VSO45UT

VSO50UT

15.0 13.5 1.4 10.2 7 x 1.3 298x4049x826

20.0 18.0 1.9 11.0 7 x 1.5 298x4049x826

25.0 22.5 2.4

32.0 28.8 3.1

36.0 32.4 3.5

40.0 36.0 3.8

44.0 39.6 4.2

48.0 43.2 4.6

9.2 7 x 1.8

10.8

8.0

7 x 2.0

9.0 7 x 2.3

7 x 2.7

8.9 7 x 2.9

9.1 7 x 2.5L

298x4049x826

298x5884x826

298x5884x826

298x5884x826

298x7689x826

298x7689x826

97

97

97

135

135

135

175

175

0.5 2501

0.5 2501

0.5 2501

1.0 2507

0.5 2560

0.5 2560

0.5 2560

0.5 2560

Heater

Model

VSO15UH

VSO20UH

VSO25UH

VSO30UH

VSO35UH

VSO40UH

VSO45UH

VSO50UH

Heat Input kW

Gross Nett

Gas

Flowrate

(m³/hr)

15.0 13.5

Injector

Pressure

(mbar)

Injector

Size

(mm)

*Size

(h x l x w)

*Weight

1.4 1.3 298x4049x826

(Kg)

97

11.0 7 x 1.5 298x4049x826 20.0 18.0

25.0 22.5

1.9

2.4

97

97

32.0 28.8

36.0 32.4

40.0

48.0

36.0

44.0 39.6

43.2

3.1

3.5

3.8

4.2

4.6

10.8

9.0 7

8.0

7 x 2.0

7 x 2.7

298x5884x826

298x5884x826

135

135

135

8.9 7 175

9.1 7 x 2.5L 298x7689x826 175

Note* For Optima heaters fitted with decorative end mouldings, Length increases by a further 1056mm, weight increases by 6Kg

25

Heater

Model

VSO15UH

VSO20UH

VSO25UH

VSO30UH

VSO35UH

VSO40UH

VSO45UH

VSO50UH

Table 6. Induced VSO Herringbone Settings - Natural Gas (G20)

Cold HB Pressure Hot HB Pressure mm H

2

O mbar mm

14.3 1.4 10.2 1.0

18.4 1.8 10.2 1.0

25.5 2.5 17.3 1.7

14.3 1.4 10.2 1.0

22.4 2.2 16.3 1.6

20.4 2.0 17.3 1.7

33.6 3.2 22.4 2.2

33.6 3.2 22.4 2.2

Table 7. Flue details - Natural Gas (G20)

Heater

Model

VSXO20UT

VSXO25UT

VSXO30UT

VSXO35UT

VSXO40UT

VSXO45UT

VSXO50UT

VSO15UT

VSO20UT

VSO25UT

VSO30UT

VSO35UT

VSO40UT

VSO45UT

VSO50UT

Mass Flow Rate of Flue

Gasses (kg/s)

Flue Pressure (Pa)

Max Flue Resistance

Flue Gas Temp (°C)

0.0130

0.0139

0.0165

19

13

33

185

205

180

0.0167

0.0183

7.5

35

185

220

0.0210 31 185

0.0224

0.0114

10

6

195

165

0.0125

0.0137

0.0189

19

28

29

190

225

205

0.0207

0.0253

24

28

235

240

0.0253 26 210

0.0257 27 220

26

Heater

Model

VSO15UT

VSO20UT

VSO25UT

VSO30UT

VSO35UT

VSO40UT

VSO45UT

VSO50UT

Tables 8. Burner Settings - Propane Gas (G31)

Heat Input kW

Gross Nett

Flowrate

(l/hr)

Injector

Pressure

(mbar)

Injector

Size

(mm)

15.0 13.9 2.18

*Size

(h x l x w)

13.5 7 x 1.0 298x4049x826

*Weight

(Kg)

97

Fan

Rating

(A)

0.5

Fan

Type

2501

20.0 18.5 2.88 12.4 7 x 1.2 298x4049x826

25.0 23.1 3.60 13.3 7 x 1.3 298x4049x826

32.0 29.6 4.60 22.5 7 x 1.3 298x5884x826

36.0 33.3 5.12 22.4 7 x 1.4 298x5884x826

40.0 37.0 5.68 18.4 7 x 1.5 298x5884x826

44.0 40.7 6.25 14.9 7 x 1.7 298x7689x826

48.0 44.4 6.82 14.3 7 x 1.8 298x7689x826

97

97

135

135

135

175

175

1.0

1.0

0.5

0.5

0.5

0.5

2507

2507

2560

2560

2560

2560

0.5 202126

Heater

Model

VSO15UH

VSO20UH

VSO25UH

VSO30UH

VSO35UH

VSO40UH

VSO45UH

VSO50UH

Heat Input kW

Gross Nett

15.0 13.9

20.0

25.0

32.0

18.5

23.1

29.6

36.0

40.0

44.0

48.0

33.3

37.0

40.7

44.4

Flowrate

(l/hr)

2.18

Injector

Pressure

(mbar)

13.5

Injector

Size

(mm)

7 x 1.0

2.88

3.60

4.60

12.4

13.3

22.5

7 x 1.2

7 x 1.3

7 x 1.3

5.12

5.68

6.25

6.82

22.4

18.4

14.9

14.3

7 x 1.4

7 x 1.5

7 x 1.7

7 x 1.8

*Size

(h x l x w)

298x4049x826

298x4049x826

298x4049x826

298x5884x826

298x5884x826

298x5884x826

298x7689x826

298x7689x826

* Weight

Note* For Optima heaters fitted with decorative end mouldings, Length increases by a further 1056mm, weight increases by 6Kg

(Kg)

97

97

97

135

135

135

175

175

Model

VSO15UH

VSO20UH

VSO25UH

VSO30UH

VSO35UH

VSO40UH

VSO45UH

VSO50UH

Table 9. Induced VSO Herringbone Settings - Propane Gas (G31)

Cold HB Pressure Hot HB Pressure mm H

2

O mbar mm

19.4 1.9 15.3 1.5

22.4 2.2 17.3 1.7

24.5 2.4 17.3 1.7

27.5 2.7 19.4 1.9

31.6 3.1 20.4 2.0

38.7 3.8 23.5 2.3

36.7 3.6 23.5 2.3

36.7 3.6 28.6 2.8

27

Table 10. Flue details - Propane Gas (G31)

Heater Model

VSO15UT

VSO20UT

VSO25UT

VSO30UT

VSO35UT

VSO40UT

VSO45UT

VSO50UT

Mass Flow Rate of Flue

Gasses (kg/s)

0.0152

0.0200

0.0196

0.0201

0.0238

0.0255

0.0210

0.0334

Flue Pressure (Pa)

Maximum Flue

Resistance

12.5

24.9

15.0

16.2

27.4

29.9

31.4

43.6

Flue Gas Temp (°C)

240

247

233

228

182

214

232

210

28

PLEASE READ this section prior to assembly to familiarise yourself with the components and tools you require at the various stages of assembly. Carefully open the packaging and check the contents against the

Please ensure that all packaging is disposed of in a safe environmentally friendly way.

For your own safety we recommend the parts and check list.

The manufacturer reserves the right to alter specifications without prior notice. use use of safety boots and leather faced gloves when handling sharp or heavy items. The of protective recommended. eye wear is also

The following tools and equipment are advisable to complete the tasks laid out in this manual.

Trestles Leather

Faced

Gloves

Wrench With

Extension

Saw

13mm

Socket

Pop

Riveter

& 3/16”

Rivets

Suitable alternative tools may be used.

Pozidrive

Screwdriver

Tape

Measure

Silicone

Sealant

& Gun

Herringbone

Systems Only

10mm,

12mm &

13mm

Spanners

4 & 5mm

Allen

Keys

2.2 Assembly Notes (refer fig’s 11-17)

2.2.1 Tubes

Identify and position tubes (A) on trestles.

Position the tubes so that the tube seams are facing inwards.

Mark out the position of the bracket centres from the dimensions shown on the assembly drawings.

U bend end

Return tube

Firing Tube

Burner end

Note:

Four module heaters (45kW & 50kW) are assembled in two sections.

Note:

First section of burner tube on

PROPANE four module heaters

(45kW & 50kW) is stainless steel.

2.2.2 Brackets

Slide the bracket assemblies (B) along to the tubes to the dimensional positions and in their correct order as detailed in the assembly drawings. We recommend brackets are fixed to tubes prior to hanging.

When fixing the bracket to the tubes it should be noted that the ‘U’ bolts on the first bracket CLOSEST TO THE BURNER* and last bracket CLOSEST TO ’U’ BEND should be tightened to achieve a minimum torque setting of 15Nm².

* not on the firing tube on 2 module versions

29

All remaining ‘U’ bolts on the RETURN

TUBE should also be tightened to achieve a minimum torque setting of 15Nm².

2.2.4 Couplers

For fixing the U bend. Locate and position tube couplers (D) Slide the coupler over the

All remaining ‘U’ bolts on the FIRING components ensuring that the rivet stop has

TUBE and the first ‘U’ bolt on the butted up to the tube end and the pre-fitted bolts

FIRING TUBE on 2 module variants, should be engage in the pre-cut holes so that the socket left loose and locked in place with a locknut to heads are FACING INWARDS. achieve a 3mm clearance above the tube to allow for thermal expansion (see sketch below).

Locknut

Return Tube Burner Firing Tube

Moving between the two set pins, tighten both ensuring that equal pressure is applied to each set pin in turn.

2.2.5 Coupler Bellows

2.2.3 Turbulators

There are various lengths of turbulators

(G) for the vision range. Identify correct lengths prior to assembly. We recommend turbulators are inserted into tubes prior to hanging.

For adjoining tubes on 3 and 4 module heaters, locate and position the coupler (Q) onto the ends of the tubes after firstly positioning a clamp on both ends. Slide each clamp onto the bellow ends.

Insert short 976mm turbulator into burner firing tube from U BEND END.

Moving between the two set pins, tighten both ensuring that equal pressure is applied to each set pin in turn.

There is one bellow located on the firing

For models 15, 20 and 25: Insert 3400mm tube on models 30, 35 & 40: turbulator into return tube from U BEND END.

There are two bellows located on each

For models 30, 35 and 40: Insert one 2600mm tube on models 45 and 50: turbulator into return tube from U BEND END

Due to the length of models 45 and 50, and one 2600mm turbulator into return tube the coupler bellows are assembled onto from OPPOSITE END. the tube ends ONCE the two halves of the turbulator into return tube from U BEND END heater have been fully assembled and

For models 45 and 50: Insert one 3040mm hung in position see “Final Fixings” section 2.2.7.2.3

and one 3400mm* turbulator into return tube from OPPOSITE END. *Nat gas only

View from U tube end

30

Fig. 11 Tube, Brackets and Turbulator detail

31

2.2.6 U Bend.

Slide U bend (C) into the open end of the couplers ensuring the pre-fitted bolts engage in the precut holes. Tighten all four clamping bolts to provide a tight grip between tubes & U bend.

To avoid damaging the heater whilst installing we recommend the heater chassis be suspended prior to fitting reflectors.

2.2.7.1 Overshield Reflectors

2.2.7 Reflectors

There are three reflector section types used in the construction on the Vision Optima heater.

Remove the protective plastic coating.

1. Overshield reflector (J): located on the underside of the inner reflector positioned

Overshields MUST be fitted prior to the assembly of the reflectors. above and in parallel to the radiant tubes.

The two ends of the overshields are different to allow for thermal expansion

Overshields (J1) are fitted to the underside of, and should be fixed in the correct order as and run in parallel to, the inner reflectors. detailed in the assembly drawings.

One end of the overshield has two holes for direct fixing to the reflector, the other end has two larger slots which along with an expansion fixing plate allows for thermal expansion.

2. Inner Reflector (H): aluminised steel reflectors located over the radiant tubes to emit the heat downwards.

3. Outer Canopy (L): pre-coated decorative reflector positioned to the outside of the reflector. The outer canopies come in two halves for ease of assembly and are held together by closing plates (N).

The overshields are supplied in two lengths and MUST be arranged, in the correct directions and on the specific reflector order as indicated in the detailed drawings.

1. Locate and position correct overshield and offer to the underside of the reflector so that the location holes are in line.

2. Using bolts, nuts and washers provided, fasten through the overshield, reflector and cross member (J2) which runs across the top.

3. The larger holes located at the other end of the overshield should line up with the holes in the reflector. This end is allowed to ‘float’ with thermal expansion and as such, an expansion plate (J3) is added and placed to the underside of the overshield.

4. Using bolts, nuts and washers provided, fasten through the expansion plate, overshield, reflector and cross member which runs across the top.

5. Continue for other reflectors.

32

Fig. 12 Overshield detail

33

2.2.7.2 Inner Reflectors

All reflectors must be positioned/ attached to the brackets exactly as detailed in the assembly drawings.

Remove the protective plastic coating.

2.2.7.2.1 Two Module units

1. Place inner reflectors (H) on the heater by sliding the reflectors between the tubes and the brackets.

2. Locate the FIRST slot on reflector over the

M8 bolt on the first bracket. Secure using large washers and anti vibration nuts.

3. The slot in other end of the first reflector should align with M8 bolt on the second bracket.

4. Locate the second reflector onto the same bolt using the SECOND slot in from the end and

OVERLAP the first reflector. This should create a 114mm overlap. Secure using large washers and anti vibration nuts.

Ensure the 2nd reflector sits on top of the 1st.

4. Locate the M8 bolts on last bracket to slot in second reflector approx one third distance from reflector end. Secure using large washers and anti vibration nuts.

5. Slight re-adjustment of brackets may be necessary for reflector alignment. Ensure U bolts are tightened correctly as described in section 2.2.3.

2.2.7.2.2 Three Module Units

1. Place inner reflectors (H) on the heater by sliding the reflectors between the tubes and the brackets.


M8 bolt on the first bracket. Secure using large washers and anti vibration nuts.

3. The slot in other end of the first reflector should align with M8 bolt on the second bracket.

4. Locate the second reflector onto the same bolt using the FIRST slot in from the end and


5. The slot in other end of the second reflector should align with M8 bolt on the third bracket.

6. Locate the third reflector onto the same bolt using the FIRST slot in from the end and

OVERLAP the second reflector. This should create a 67mm overlap. Secure using large washers and anti vibration nuts.

Ensure the 3rd reflector sits on top of the 2nd reflector and the 2nd reflector on top of the 1st

7. Locate the M8 bolts on last bracket to slot in third reflector approx one third distance from reflector end. Secure using large washers and anti vibration nuts.

8. Slight re-adjustment of brackets may be necessary for reflector alignment. Ensure ‘U’ bolts are tightened correctly as described in section 2.2.3.

2.2.7.2.3

Four Module Units.

Models 45 and 50 are assembled in two halves.

Working on the half closest to the Burner:

1. Place the first two inner reflectors (H) on the heater by sliding the reflectors between the tubes and the brackets.


M8 bolt on the first bracket on this half. Secure using large washers and anti vibration nuts.

3. The slot in other end of the first reflector should align with M8 bolts on the second bracket on this half.

4. Locate the second reflector onto the same bolt using the FIRST slot in from the end and


34

Ensure the 2nd reflector sits on top of the 1st.

5. Locate the M8 bolts on third bracket on this half to slot in same reflector approx one third distance from reflector end. Secure using large washers and anti vibration nuts.

Now working on the second half:

6. Place the remaining inner reflectors (H) on the heater by sliding the reflectors between the tubes and the brackets.

2.2.8 Insulation mats.

Using the recommended safety equipment i.e. gloves, goggles and a face mask, cover the back of reflectors with the insulation mats. Tuck in the edge of the mat behind the lip of the reflector.

The insulation mats come in two sections for the four module variants.

Note: Third reflector ONLY is turned through 180° to all other reflectors.

7. Locate the fourth reflector onto the M8 bolts of the first bracket on this half using the slot approx one third distance in from the end of the reflector. Secure using large washers and anti vibration nuts.

8. The last slot in other end of this reflector should align with M8 bolts on the second bracket on this half.

9. Locate the fourth reflector onto the same bolts using the FIRST slot in from the end and

OVERLAP the third reflector. This should create a 84mm overlap. Secure using large washers and anti vibration nuts

Ensure the 4th reflector sits on top of the 3rd.

10. Locate the M8 bolts on last bracket to slot in fourth reflector approx one third distance from reflector end. Secure using large washers and anti vibration nuts.

11. Slight re-adjustment of brackets may be necessary for reflector alignment. Ensure ‘U’ bolts are tightened correctly as described in section 2.2.3.

Final fixings for four module units.

12. At this stage, with the bellow couplers already affixed to one half, align and offer other side of bellow couplers to adjoining tubes, carefully overlapping the second reflector to the third to create a 50mm overlap. Secure using bolts, large washers and anti vibration nuts.

13. Tighten bellow couplers as stated in section

2.2.5

14. With the assembly correctly fitted, a gap of

1120mm between brackets 3 and 4 should be apparent.

35

Fig. 13 Reflector detail

36

2.2.9 Outer Canopy's

other and insert M8 self tapping screws provided.

6. Repeat the procedure for 3rd set of outer canopies.


2.2.9.3 Four Module Units

1. Slide on the two halves to cover the centre section of the heaters and fit closing plates to each end (P).

2. Slide on two more outer canopies.

3. Stop short of the canopies already fitted and

The outer canopies are made up of identical half fit closing plates (P). following method; covers (L) which engage into the side of the

4. Insert the ends of the second set of canopies inner reflectors and join at the centre by way of a closing plate which holds the two halves together. Install the outer canopies using the inside the first set at the central joint.

5. A slot is located 15mm from the end of each canopy. Align each slot i.e. one on top of each

2.2.8.1 Two Module Units other and insert M8 self tapping screws provided.

1. Slide on the two halves to cover the 1st sec-

6. Repeat the procedure for 3rd and 4th set of tion of the heaters and fit closing plates to each end to the second set of canopies. outer canopies.


3. Stop short of the canopies already fitted and fit closing plates (N).

4. Insert the ends of the second set of canopies inside the first set at the central joint.

5. A slot is located 15mm from the end of each canopy. Align each slot i.e. one on top of each other and insert M8 self tapping screws provided.

2.2.8.2 Three Module Units

1. Slide on the two halves to cover the centre section of the heaters and fit closing plates to each end (P).


3. Stop short of the canopies already fitted and fit closing plates (P).

4. Insert the ends of the second set of canopies inside the first set at the central joint.

5. A slot is located 15mm from the end of each canopy. Align each slot i.e. one on top of each

37

Fig. 14 Canopy detail

38

2.2.10 End Caps


Position the end cap with no tube holes (M) beneath the reflector profile at the U bend end making sure that the end cap engages inside the inner reflector . Fasten to canopy using M5 pozi set pin and washers.

Position the end cap with tube holes beneath the reflector profile at the burner end making sure that the end cap engages inside the inner reflector . Fasten to canopy using M5 pozi set pin and washers.

2.2.13 Fan Assembly

On unitary heaters only, slide the fan assembly (E2) onto the LEFT HAND TUBE

with the test point closest to the tube when viewed from behind ensuring it is fully engaged.

Secure with pinch screws.

2.2.14 Herringbone Damper Assembly

2.2.11 Burner Assembly.

On Herringbone heaters only, slide the

Slide the burner assembly (F) onto the RIGHT

HAND TUBE when viewed from behind, damper assembly (E3) onto the LEFT HAND

TUBE with the test point closest to the tube when viewed from behind ensuring it is fully ensuring it is fully engaged. Secure with grub engaged. Secure with pinch screws. screws.

2.2.12 Heat Exchanger Assembly

On VSXO only, slide the heat exchanger assembly (E1) onto the LEFT HAND TUBE when viewed from behind ensuring it is fully engaged. Secure with pinch screws.

Note: The damper assembly must be located with its damper blade vertical and left in the closed position. The manifold tube is to be sealed and secured (as described below) to the damper assembly.

39

FLOW

Manifold Tube Damper Blade

Vacuum Test Point

Emitter Tube

FLOW

External bead of jointing compound

Fitting

2.2.15 Fixing of optional End Mouldings.

If end mouldings (P) have been ordered

(optional item) fit the end mouldings with the screws provided / quick release clips to the holes in top of the canopy.

Manifold

Internal bead of jointing compound

Note The silicon jointing compound remains workable after application for only 5 minutes.

Secure the joint by drilling through the tube and fitting and fix with three pop rivets at 12 o’clock,

4 o’clock and 8 o’clock positions. 4.8mm

(3/16in) diameter pop rivets are recommended.

2.2.16 HB Manifold Assembly.

VSO Models ONLY. After fixing the heaters in the desired position, the manifold system requires fitting.

After allowing for a minimum of 75mm (3in) of penetration of the fitting into the tube, cut the tubes to the lengths required and remove all

The following pages show the exploded diaburrs and wipe off any grease or oil with a clean rag. grams of the VSO and VSXO range of heaters.

Please note the heater type, length and reference number from the delivery/advice note

Method of jointing aluminium tube

Using the applicator gun exude 4mm diameter

2.2.17 Detailed Assembly Drawings

before identifying the correct model drawing bead of high temperature silicon jointing compound externally round the end of the fitting and internally round the end of the tube.

Enter the fitting into the tube using a slight rotating movement to spread the jointing compound uniformly until a penetration of 75mm

(3in) is achieved.

40

41

42

43

These appliances should be commissioned by a qualified engineer.


Leather Faced

Gloves


Pozidrive

Screwdriver

Small Flat Head

Screwdriver

Large Adjustable

Spanners or 22, 26 &

27mm Spanners for fitting Of Gas Flex.

Wrench with

Extension

12mm

Spanner

13mm

Socket

4mm Allen Key

Manometer

3.2

Balancing The Herringbone System

Important. When all the heaters have

Start all burners up and allow them to run for at least 20 minutes. been installed the vacuum settings must be finally balanced in the hot condition. Adjust the damper at exit of each heater using a

4mm Allen key in the damper blade securing

Before attempting to start up the heating screw. Observing the vacuum reading using a system it is essential to perform the preliminary ‘U’ tube manometer connected to the vacuum balancing of the vacuum level at each burner test point (see over) each damper should be unit. Isolate each heater unit by unplugging the readjusted and set at a hot condition reading as electrical connector and closing the gas shown in table 6 for the appropriate size of isolating valve. heater and model.

Figure 18. HB Damper Assembly

B C

A

Ref Description

A Radiant Emitter Tube

B Manifold Tube

C Damper Blade

44

Slacken screw in burner lid and open the right hand burner access door.

The two vacuum impulse hoses are in view.

Both hoses are fitted with ‘T’ pieces, one end of which has a blanking cap.

Connect extra sections of hose to each ‘T’ piece.

Remove each blanking cap.

Connect either a digital manometer or U tube gauge to the open ends of the hoses.

45

Check reading against technical data.

3.3

Commissioning chart

Check installation has been carried out to these instructions.

Ensure gas and electricity supplies are isolated.

Disconnect gas hose from burner

Remove burner from tube and inspect burner head.

(See servicing instructions)

Replace burner on tube and secure.

Reconnect gas hose.

Open isolating valve.

Check soundness.

Open control housing and check that all components are securely fastened.

Check thermostat is set to maximum and is calling for heat.

The heater should now run through its start up sequence and ignite.

Switch on electrical supply.

The red neon should now be illuminated. If restarting heater a delay of 15s should be allowed.

A successful ignition is indicated by the amber light illuminating and remaining illuminated.

Turn off power and check that all components are securely fastened.

NO

Has the burner lit?

YES

Check gas pressure.

Check operation on flame failure.

Check gas pressure.

Figure 19. Gas Valve adjustment

Gas inlet test point

Check operation of air pressure switch.

Close control housing

Injector pressure test point.

Adjustment screw under cap to set injector pressure

46

Leave the instructions with a responsible person.

These appliances should be serviced annually by a competent person to ensure safe and efficient operation. In exceptional dusty or polluted conditions more frequent servicing may be required. The manufacturer offers a maintenance service. Details

available on request



Leather

Faced

Gloves

Pozidrive

Screwdriver

Small Flat

Head

Screwdriver

Large Adjustable

Spanners or 22, 26 &

27mm Spanners for

Fitting of Gas Flex.

12mm

Spanner

4mm

Allen

Key

Manometer

Wrench with

13mm

Socket

Soft

Brush

K

Figure 20. Induced Herringbone Burner: Model VSO UT/UH (refer to spares section 5)

L M

N

A

B

C

J

H

A Ducted Air Inlet

B Induced Air Inlet

C Gaskets

D Ignitor Assembly

E Pepperpot Head

F Multi Hole Injector

G Ignition Controller

H Pressure Switch

G

47

F

E

J

K

L

M

N

Neon’s (Red/Amber)

Gas Valve

Mains Input Socket

Fan Socket

Injector Carrier

D

Figure 21. Forced Gas Burner:

Model VSXO (refer to spares section 5)

H Multi Hole Injector

A 2501/2507 or 2560 Fan

B Fan Inlet Spigot

K Extrusion Burner Head

D Fan Mount Plate

E Fan Mount Plate Gasket

Please refer to spares for burner components

4.3 Burner Removal (All Options)

Step 1 Isolate mains electric and gas supplies.

Step 2 Detach the gas supply as shown below, taking care to support the burner connection.

48

Step 3 On forced burners with ducted air disconnected by separating the connectors of attachment, slacken jubilee clip and remove flexible hose from the fan. the ignition lead assembly and removing the pressure switch silicon tube.

Step 4 Slacken both grub screws on the burner Step 3 The gas injector can be inspected and support casting using a 4mm Allen key to replaced if contaminated or blocked. enable the burner to be removed from the radiant tube.

Step 5 Carefully remove the burner to prevent it or any components from falling to the ground and position the assembly in a safe area.

4.4 Burner Gas Injector Servicing

Step 1 Remove the burner support casting and gasket.

When replacing the gas injector use a

12mm spanner and ensure approved thread sealant is used.

Step 4 Refit the burner support casting and replace the gaskets to ensure effective sealing.

4.5 Burner Head and Electrode Servicing

Step 1 Check the pepper pot burner head for contamination. If necessary the head can be removed for cleaning of the inside of the burner head, see below.

Step 2 The burner head assembly can be

49

Step 2 The pepper pot burner head can be replaced ensuring the 5 holes on the outer ring are aligned alongside the probes.

Step 2 Loosen the 4mm grub screw and de-tatch the combustion fan.

Step 3 The condition of the ignitor assembly can be checked for deterioration. However, we advise replacement at each service to ensure continued reliability.

Step 4 Detach the electrode assembly from the burner head by removing the two screws and separating the ignitor lead connectors.

Step 5 Check the positions and spark gap as shown below.

Step 6 The burner assembly is ready to refit after servicing the combustion fan and the radiant tube assembly.

4.6 Combustion Fan Assembly Unitary heaters

Step 1 Loosen the clamp fitting on the flue

Step 3 Remove the fan orifice plate spinning.

50

Figure 22. Burner head detail

Step 4 Inspect the impeller and remove any dust with a soft brush.

Step 5 Remove any dust from fan scroll and from around the motor.

Step 6 Ensure the impeller rotates freely.

Step 7 Refit components.

4.7 Combustion Fan Assembly Powered

Burner

Step 1 Slacken jubilee clip and remove the flexible hose from the fan.

Step 5 Inspect the impeller and remove any dust with a soft brush.

Step 6 Remove any dust from fan scroll and from around the motor.

Step 2 Remove fan fixings.

Step 7 Ensure the impeller rotates freely.


4.8 Radiant Tube Servicing

Step 1 Brush any dust from the exterior of the tubes.

Step 2 Inspect the fan and burner tubes visually.

If the tubes appear clean, skip to servicing the reflector.

Step 3 Remove the U bend

Step 3 The combustion fan can now be detached.

Step 4 Remove the fan orifice plate spinning.

51

Step 4 Withdraw the turbulators from the Step 2 Slacken casing support screws and appliance. Carefully noting their condition and position. Replace turbulators if necessary. remove heat exchanger from the radiant tube.

Step 5 The turbulators should be cleaned with a soft brush.

Step 6 If required the interior of the tubes can then be cleaned using an industrial vacuum cleaner or by using long poles and a scraper.


4.9 Heat Exchanger Servicing

Step 1 Remove the flue connections.

Step 3 Remove any dust and dirt from the heat exchanger & refit.

4.10 Reflector Servicing

The condition of the reflectors should be noted.

If necessary the reflectors can be cleaned with a mild detergent.

This can significantly improve the efficiency of the appliance.

4.11 Inspection of Flue

The flue needs to be inspected and cleaned if necessary or in accordance to the regulations of the country that the appliance is installed.

4.12 Re-commissioning After Service

After servicing of the heater has been undertaken, it will be necessary to re-commission the heater as detailed in Section

3 of these instructions.

52

Required Spares (refer to section 4.2)

In order to aid troubleshooting and servicing we recommend that the components shown in this section should be stocked.

Item Description Part No.

Note Any spare part components that are not approved by AmbiRad could invalidate the approval of the appliance

and validity of the warranty.

Item Description Part No.

Ignition

Controller

2015S

Pressure Switch:

VSXO (Red)

VSO (Green)

201676

201508

Twin Gas Valve:

Nat Gas

Propane

201587

201914

Amber Neon

(Burner On)

2175

Pepperpot Head 200988

Red Neon

(Mains On)

2180

Ignitor Assembly 201284 Combustion Fan

See

Section 1.11

Extruded Burner

Head

200358

Injector

See section 1.11

Gasket Set

Ducted Air Hose

Hose Clamp

201488

201321

7541

Jet Carrier 200420

Jet Carrier

(VSO / VSXO50

NG)

201630

Flame Plates:

(VSO15/20/25 NG

& VSXO20/25 NG)

(VSO15/20/25/30

Propane)

(VSO35/40/45/50

Propane)

201854

201571

201905

Cables:

Spark Electrode

(black)

Rectification lead

(purple)

Earth lead

(green/yellow)

GV Mini Harness

900225-2

900225-3

900225-1

900375

53

Ensure gas & electricity supplies are enabled.

YES

YES

Check:

1. Burner controller

2. Red neon faulty

Does the RED neon

illuminate?

NO

Is there power on the burner?

NO

Check:

1. Operation of any thermostat

2. Any external fuses

3. Correct voltage is selected

YES

Does the combustion fan run?

NO

Check:

1. Wiring harness & plugs

2. Vacuum switch operation

3. Replace fan

YES

NO

Check:

1. Vacuum switch tubes

2. Emitter tubes, air inlet & flue for obstructions

3. Operation of vacuum switch

4. Replace combustion fan

Does the amber light illuminate after

10s purge?

NO

Does the vacuum switch

`pull in`?

Check:


2. Wiring harness

3. Amber neon faulty

YES

YES

Does the amber light illuminate for 10s then go out?

YES

NO

If the heater still fails to operate normally, please contact the AmbiRad service department.

Is the burner sparking?

YES

NO

Check:

1. Integrity of spark leads

2. Integrity of electrode assembly & spark gap


Does the gas valve open?

NO

Check:


2. Replace gas valve

YES

Check:

1. Burner inlet pressure

2. Burner nozzle pressure

3. Check live & neutral polarity

4. Check presence of good earth

54

7.1.1 Burner Controller Replacement (VSXO)

Step 1 Slacken screw in burner lid and open the right hand burner access door.

Step 2 Undo 2 screws from controller bracket and remove. Disconnect burner controller from the wiring harness.

7.1.2 Burner Controller Replacement (VSO)

Step 1 Slacken screw in burner lid and open the right hand burner access door.

Step 2 Disconnect burner controller from the wiring harness.

Step 3 Disconnect the HT Lead from burner controller.

Step 3 Disconnect the HT Lead from burner controller.

Step 4 Remove the four screws attaching the controller to the bracket and remove.

Step 4 Remove the two screws attaching the controller to the burner and remove.

Step 5 Fit new burner controller

Step 6 Refit HT leads and refit burner controller to wiring harness.

Step 7 Test product and close access doors.

55

Step 5 Fit new burner controller

Step 6 Refit HT leads and refit burner controller to wiring harness.

Step 7 Test product and close access door.

7.2 Air Pressure Switch Replacement

Step 1 Disconnect the two silicone impulse tubes and three wiring connections making note of replacement positions.

7.3 Gas Valve Replacement

Step 1 Remove the burner assembly as described in the section 4.3 Servicing.

Step 3 Open the left hand access door and detach the impulse hoses from the air pressure switch.

Step 2 Remove the two screws as shown below.

Step 4 Remove the 4 screws holding the burner head onto the burner assembly.

Step 3 The air pressure switch can now be removed.

Step 4

Fit the new air pressure switch ensuring the impulse tubes are connected as shown below.

Step 5

Test product a n d c l o s e access doors.

56

Step 5 The burner head can now be detached by disconnecting the impulse tube and the burner head wiring.

Step 6 Detach the two screws holding the front of the gas valve.

Step 7 Remove the four screws holding the rear burner plate in position plus the two screws from the gas valve flange.

Step 11 The gas valve can now be replaced.

Step 12 Refit all components in reverse order.

Step 13 (For Natural Gas burners ONLY).

Ensure step screw is in the correct position as indicated in the diagram below.

Step 8 Remove the rear plate.

Step 9 The jet carrier, gas inlet, and wiring harness can now be detached from the gas valve.

Step 10 The two screws retaining the gas valve can then be removed.

Step 14 Set gas pressures to data badge or as per section 1.11 and ensure reliable burner performance.

Step 15 Test product and close access doors.

57

Notes

58

Notes

59

8. User & Operating Instructions.

8.1 To Start the Heater

1. Ensure gas supply is turned on.

2. Electrical supply to the controls is on.

3. Ensure that the controls are correctly set i.e.;

•

•

•

Clock is correctly set.

Heater program is correctly set.

Required room temp is correctly set

4. Once the heating controller ‘calls for heat’ power will be supplied to the heater(s). The red neon will then illuminate.

5. After a pre-purge period of 10 seconds the burner will ignite and the amber neon will then illuminate.

6. If lockout occurs press the lockout reset button (if available), or switch off electrical supply and restart after 15 seconds.

7. If lockout occurs three times consecutively switch off and isolate the gas and electricity supplies.

Contact the AmbiRad Service department.

8.2. To Switch Off Heater

1. Switch off electrical supply to the heater.

The burner will stop and the fan will shut off.

2. If the heater is to be switched off for periods in excess of one week it is highly recommended that both the gas and the electrical supplies are turned off.

8.3. Routine Maintenance between Service

Intervals

After ensuring that the heater is cold and mains electric isolated, cleaning of the reflectors with a soft cloth and a mild detergent (non solvent based cleaners only) in water can be undertaken.

Additional removal of dust from the radiant tubes, burner and heat exchanger can be undertaken.

8.4 Frequency of Servicing

The manufacturer recommends that to ensure continued efficient and safe operation of the appliance, the heater is serviced annually by a competent person e.g. every year in normal working conditions but in exceptional dusty or polluted conditions more frequent servicing may be required.

The manufacturer offers a maintenance service.

Details are available on request.

AmbiRad.

For further technical and service support visit our Support Information Database at www.s-i-d.co.uk

For Service requirements, please contact

AmbiRad Limited Fens Pool Avenue

Brierley Hill West Midlands DY5 1QA

United Kingdom.

Telephone 01384 489700

Facsimile 01384 489707

Email [email protected]

Website www.ambirad.co.uk

Technical Support www.s-i-d.co.uk

AmbiRad is a registered trademark of AmbiRad Limited. Because of continuous product

60

Ambirad VISION VSO Operating instructions

SSEMBLY

NSTALLATION

ERVICING

ANUAL

®

INDEX

Section

WARNINGS

AmbiRad equipment must be installed and maintained in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired products.

Due account should also be taken of any obligations arising from the Health and Safety at

Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896 (Industrial &

Commercial) and any other relevant British Standards and Codes of Practice by a qualified installer. All external wiring MUST comply with the current IEE wiring regulations.

Introduction.

Document Index.

1 Installation Requirements

2 Assembly Instructions

3 Commissioning Instructions

4 Servicing Instructions

5 Spare Parts

6 Fault Finding Guide

7 Replacing Parts

8 User and Operating Instructions

1.1 Health and Safety

1.5 Herringbone Systems (VSOUH).

1.6 Clearance to Combustibles.

VSXO

20/25 30/35/40 45/50

VSO UT

15/20/25 30/35/40 45/50

VSO UH Herringbone

15/20/25 30/35/40 45/50

1.7 Gas Connection and Supply

GREY

C.

N.O.

VACUUM

SWITCH

N.C.

SOLENOID VALVE

VALVE

J.S.T.

1 2 3

GRN/YLW

BLUE

BLUE

N

L

FAN

GREEN/YELLOW

EMC FILTER

MAINS INPUT

L N

BURNER

ON

MAINS

ON

LAMPS

BLUE

BROWN

BROWN

WHITE

MAIN J.S.T.

9

1 2 3 4

7 8

10 11 12

PINK

YELLOW

GREY

1.9 Ventilation Requirements

1.10 Flue and Combustion Air Inlet -

Options

1.10.1 Important Information

1.10.3 Condensation

1.10.4 Method of Jointing Tube

1.11 Technical Details.

2.2 Assembly Notes (refer fig’s 11-17)

2.2.1 Tubes

2.2.2 Brackets