ARO SERIES

OIL FIRED

TUBE HEATER

Installation and operating manual

Index

1 Commissioning, service and warranty

2 Health and safety

3 Electrical installation

4 Heater suspension & mounting heights

5 Clearance distance to combustible surfaces

6 Heater assembly

7 Flue details

8 Ventilation requirements

9 Ducted air for polluted/dusty atmospheres

10 Oil type and supply details

11 Routine servicing and fault finding

12 Replacement of parts

13 Parts: Spares and installation

1 Commissioning, service and warranty

Commissioning

After installation in accordance with these instructions please contact Ambi-Rad

Service on 01384 489700 to arrange commissioning of the product.

Note Failure to observe the above will invalidate the warranty.

Service

To ensure continued and safe operation it is recommended that the heater is serviced every 6 months.

The manufacturer, whose address is provided at the back of these instructions, offers a maintenance service. Details available on request.

Warranty

All parts and labour are covered for a period of 12 months from the date of commissioning. Any consumable parts such as the burner nozzle used on routine service are excluded from the warranty.

Please contact Ambi-Rad Service on

01384 489700 for further details.

2 Health & safety

Sole liability rests with the installer to ensure that all site safety procedures are adhered to during installation.

Sole liability rests with the installer to ensure that protective safety wear such as hand, eye, ear and head protection is used during installation of the product.

Direct contact with oils or insulation without the use of safety protection must be avoided.

Do not rest anything, especially ladders against the heater.

All installations must be in accordance with the regulations in force in the country of use.

Installers must be able to demonstrate competence and be suitably qualified in accordance with the regulations in force in the country of use.

These instructions must be given to the user on completion of the installation.

3 Electrical installation

Ensure the burner has a permanent live supply in addition to the switch live supply.

This appliance must be earthed.

Electrical supply must be via a fused double pole isolator having a contact separation of >3mm in all poles. The installation shall conform to the regulation in force in the country of use.

Switching and control is recommended on the live conductor.

Supply 230V 50Hz single phase.

Current rating 0.7 amp max (inductive).

Fuse rating 5 amp per heater.

The plug supplied with the burner must be wired as shown in the wiring diagram.

(See Fig 1 page 2).

For economic control of the heater(s) the installation of a black bulb thermostat is recommended and available from the manufacturer.

Remote reset of control box is possible via a momentary switch that is available from the manufacturer.

1

Figure 1 Wiring diagram

Oil Burner Wiring

7 Way Plug and Socket

Field Wiring

2

B Photo resistor

TV Transformer - ignition

MV Burner motor

V1 Oil solenoid valve

V2 Extra safety oil solenoid valve

SA External lockout lamp (optional)

RC External reset lockout (optional)

(AR Part No 200159)

RT Control thermostat

HS Mains switch

4 Heater suspension and mounting heights

The weight of the heater is approx. 100kg.

Attachment of the heater support brackets to the building structure must be made using 4mm welded link chain and speed links. Alternatively 10mm diameter closed loop drop rods.

The U Tube heater must be suspended from a minimum of 2 support brackets.

First and third brackets from the burner end or first and forth. See Table 2/Fig 2.

It is the sole responsibility of the installer to ensure that the points of attachment to the building are sound. Consultation with the consultant/architect or owner of the building is recommended to ensure that a sound, mechanically stable installation is achieved.

Please refer to diagram and tables on this page.

Table 2

Required angle

Chain length

Eye bolt position

All dimensions in mm.

60˚,

2 links,

Table 1 Mounting heights from floor

Model

Horizontal

Minimum mounting height

Recommended mounting height range

When mounting over these heights contact

Ambi-Rad Design office

4000

4900 - 11000

Over 11000

Figure 2

1.

2. 3.

ARO40

Inclined/wall

3600

4000 - 7000

Over 7000

C

E

Note If heater is to be mounted at an angle (Fig 2) the burner must be on lowest leg.

45˚,

18 links,

3 U Tube

30˚

15 links

Important The heater should slope downwards towards the return bend by approx 20mm for both horizontal and wall mounted installations.

5 Clearance distance to combustible surface

Figure 4

A

250mm

Figure 3

Table 3 Clearance distances

Above reflector

Beneath tubes

To the sides

All dimensions in mm.

A

C

D

All models

420

2300

1480

3

6 Heater assembly U Tube

Figure 5

4

6 Heater assembly SL

Figure 6

5

7 Flue details

Flue details

Each heater must be individually flued.

Stainless steel twin wall flue is recommended to minimise condensation.

The product must be used with a flue to the outside.

Flue diameter 100mm (4”).

An approved terminal must be used.

Maximum flue length is 4m (13ft).

Flue termination must be vertical.

Maximum bends : 2

8 Ventilation requirements

Permanent ventilation must be ensured.

Natural Ventilation

(Preferably at low level)

Up to and including 60kW: 4.5cm

2 /kW.

Over 60kW : 270cm 2 + 2.25cm

2 /kW in excess of 60kW total rated input.

Forced Ventilation

Minimum proven air flow is 2.35m

3 /h/kW of total rated input.

9 Ducted air for polluted/dusty atmospheres

A fresh air ducted inlet is available as an option to prevent ingress of process dust, chlorinated vapours etc. If installation is in a potentially polluted atmosphere the installer must consider prior to installation, the requirement for this option. The ducted air inlet is to be connected between the burner and a suitable 100mm ducted air feed pipe to outside.

10 Oil type and supply details

Technical data

Model

ARO40

Fuel type

Oil supply connection

Heat input Gross

Heat input Nett

Flow rate Lts/Hr

Gals/hs

Nozzle size/Spray Angle

Burner pump pressure

Bar

PSI

35 sec gas oil class D visc 1.5E at 20˚C

RC 1 / 4 BSP Male

38kW

35.7kW

3.6

0.8

Danfoss 0.85 30S

9

130

Note Only use nozzles of identical type as supplied by manufacturer

Pre heater

In cold climates with continued sub zero temperature, consideration must be given to heating and lagging of the oil tank.

Insulate external pipework to reduce the potential of freezing.

To prevent freezing ensure winter grade fuel is used during the winter.

Fire valve

A fire valve (operating temperature 70˚C) must be utilised to sense each burner installed. The oil shut off valve should be sited externally of the building. (See Fig 7 and 8. Page 7 on the feed from the storage tank.

Lift Pumpset

Where a lift pump set (Part No 200140) is used it is recommended that the pump is wired into the control panel to give continuous oil circulation. This will assist in preventing waxing of the oil during the winter period and also ensure a continuous delivery of oil to the burners.

Flexible oil lines

Where the flexible oil lines connect between the fixed oil supplies and burner, do not allow lines to become stretched or stressed allow ‘Easy’ bends, which will compensate for expansion of the heater.

Pre heater

If temperatures are likely to fall below

-4˚C. A burner with pre- heater should be used to stop waxing of the oil.

The oil supply line shall be sized to ensure that the required flow rate at the burner is achieved at all times.

Oil lifter installation see Fig 7. page 7

(Single Burner). Lift pump/installation. See

Fig 8. page 7. (Multiple Burner).

It is recommended that isolation valves are provided to facilitate servicing. Oil storage tanks must be installed outside the building in accordance with the regulations in force.

• A ring main pressure of min 0.5 to 1.5 bar gauge must be used.

• Use pressure regulating valves as appropriate. The flexible oil line must be used to allow for expansion of the heater.

6

Figure 7 Single Burner Installation (with part number identification)

Terminal

Fire Protection

200137 -15*

* If total length of capillary is greater than 15m to burner use

200251/252+

200143

200138

Oil

Lifter

300mm to 2500mm

200148 De-Aerator c/w combined valve

Burner

Oil Storage

Tank

200141/229

Isolating valve

200147/146

Filter

(With Part No Identification)

Schematic Single Burner Installation

Figure 8 Multiple Burner Installation (with part number identification)

Flue

200mm to

800mm

Terminal

Pressure

Setting

Valve

Pressure

Gauge

201072/073/

074

Back pressure relief valve

201071 Filter

200141/229 Valve

201076

Pressure Gauge

200140

Transfer Pump

200141/299

Isolating Valve

200147/146

Filter

200251/252

Solenoid Firevalve

Flue

Thermolink 200143

(With Part No Identification)

Schematic Multi Burner Installation

Flue

200mm to

800mm

Burner

Pressure setting valve

7

Burner start up procedure

Turn on the oil supply, connect electrical supply. Ensure that the thermostat and time clock are calling for heat. Bleed the air through the pump by slackening the oil pump plug.

Observe start up sequence;

• 1 Fan runs

• 2 Spark ignition is energized

• 3 Oil solenoids open

• 4 Ignition successful

If ignition fails air may still be present within the system. Purge the air as necessary. Depress lockout reset to restart ignition sequence.

Turn off electrical supply and attach the oil pressure gauge to pressure gauge port on pump firstly removing oil pump plug.

Note Where a deaerator is used, release the air through knurled nut on the top of the deaerator.

Reconnect the electrical supply. Check the oil is set to 130psi (9bar) if necessary adjust at oil pump with a suitable allen key.

During this purging sequence the burner may go to lock out.

Depress lockout reset.

+

Once the air is purged, retighten the oil pump plug.

Check air regulator is set to 4.5.

Run the burner for a minimum of 15 minutes, then check the combustion products in the flue with a suitable gas analyser adjust air regulator to give CO2 of 10-10.5% and a smoke No. 0.

Figure 11 Air regulation

To adjust air flow, loosen the two screws ‘B’ and turn the air damper as required.

Re-tighten the screws ‘B’.

If adjustment is required see Figure 11.

8

11

Routine servicing and fault finding

Radiant tube inspection.

Brush away any dust on the exterior of the emitter tubes.

To remove the burner

Disconnect electrical supply by slackening two M8 bolts, twist burner and remove.

Inspect the emitter tubes internally. If there is any appreciable build up of dust or deposits the tubes should be cleaned internally.

Detach return bend and remove the turbulators. The two tubes can then be cleaned by passing rods and a suitable scraper through them or by use of an industrial vacuum cleaner with a long extension.

Check burner

Remove 3 screws securing air intake and use soft brush.

Figure 9

Clean impellor externally

3 mm

Remove 4 screws securing pump cover.

3 mm

Clean impellers internally.

Check and clean pump filter.

5/6mm

Replace burner mounting gasket at each service. (See above).

Reflector

The reflectors can be cleaned with a soft cloth and detergent in water. A mild non abrasive metal polish may be used in cases of extreme discolouration. Dirty reflectors will increase the heat radiation upwards into the roof space by 3-4%.

Flexible oil line

The flexible oil lines should be replaced annually.

Oil filters to the burner

Inspect and clean filter elements and replace elements where necessary.

Recommission heater follow burner start up procedure.

Open access door. Remove 2 screws.

• Clean diffuser.

• Electrodes replace or clean as necessary.

Ensure correct position as Figure 9.

• It is necessary to replace the nozzle at each service to gain access. Follow steps in section 12 Replacement of Parts.

9

Figure 11

Priming and adjustment of the pump (Fig.10).

1. Inlet

2. Return

3. Bleed and pressure gauge port

4. Vacuum gauge port

5. Pressure adjustment

6. Nozzle outlet

Trouble shooting checklist

Symptoms

Burner will not start

Ensure burner lockout has been reset.

Burner pre-purges and stops

Burner does not spark during cycle and stops

Burner does not ignite

Burner ignites and then stops

Fault check

Mains switch not on.

Blown fuse.

Timer/thermostats not made.

Fault in control box or fan motor.

Fault in control box

Photo cell. Seeing the light or faulty.

Transformer.

Fault in control box.

Dirty ignition electrodes or incorrect setting.

Fault ignition transformer.

Blocked nozzle.

oil solenoid failure.

Oil pressure too low/Check oil supply.

Blocked oil filter.

Excessive combustion air for nozzle capacity/check air setting

Fault in control box.

Faulty nozzle.

Photo-resistor does not ‘see’ flame.

Excessive combustion air for nozzle capacity.

Fault in control box.

Oil pressure too low.

Blocked oil filter.

10

12 Replacement of parts

Disconnect electric and oil supplies to the burner. Remove the burner by slackening two M8 bolts - twist and remove the burner.

Removal of blast tube.

Note When refitting, ensure the diffuser sits against top of the screw head.

Removal of nozzle

Using a suitable spanner grip nozzle and remove, use a second spanner to stop the nozzle assembly rotating.

To Replace the Motor

Disconnect oil pump by slackening 3x grub screws. Remove 2 screws open access door.

Slackening grub screw

Remove blast tube by twisting and pulling outwards.

When replacing nozzle, do not touch front face of the nozzle.

Do not overtighten the nozzle when replacing, as this may damage the sealing face.

To Replace the Pump

Remove oil lines. Disconnect solenoid coil.

Disconnect oil feed line to burner.

Slacken 3 grub screws and remove pump.

Release the fan impellor by slackening grub screw through access door.

Remove 3 screws securing motor to burner body. Disconnect electrical connection to control box.

Note When refitting blast tube do not overtighten grub screw.

Removal of ignition electrodes.

Remove securing screw.

When refitting, ensure pump coupling locates correctly into the motor.

To Replace Transformer

Remove screws securing access door and lift. Remove screws securing transformer.

Disconnect electrode leads. Disconnect wiring from control box.

Note When replacing electrodes - Ensure setting positions are correct. See Fig 9.

Removal of diffuser

Slacken grub screw and remove diffuser.

11

To Replace the Photo Resistor

Pull out of location. Depress clip and pull photo resistor from the socket.

Note When replacing ensure photo resistor cell faces forward towards blast tube.

12

13 Parts : Spares and installation

Description Part Number

Oil Pump 200154

Motor 200153

200152 Nozzle

Secondary solenoid 200149

Blast tube 200151

Electrodes 200158

Diffuser 200168

Electrode leads 200162

Control box 200160

Photo resistor 200150

Transformer 200157

Description

Nipple/washer

Part Number

200156

Primary solenoid 200164

Oil hose 200155

Pump coupling 200161

Gasket 200008

Oil line filter 201071

Pump filter 201095

De-aerator 200148

De-aerator filter 201075

Pre-heat kit

Turbulator

Burner Leg

Turbulator

Flue Leg

200603

200015T

6602

13

BCEMA

Ambi-Rad Limited Fens Pool Avenue

Brierley Hill West Midlands

DY5 1QA United Kingdom

Telephone 01384 489700

Facsimile 01384 489707

UK sales email [email protected]

Website www.ambirad.co.uk

is the registered trademark of Ambi-Rad Limited.

Due to continuous product innovation, Ambi-Rad reserves the right to change product specification without due notice.

Document reference number GB/ARO/104/1104