OPTIMA Operation, maintenance and servicing manual RADIANT TUBE

OPTIMA Operation, maintenance and servicing manual RADIANT TUBE
OPTIMA
RADIANT TUBE
HEATING SYSTEMS
Operation, maintenance
and servicing manual
CONTENTS
GENERAL INSTRUCTIONS
Section
Title
Page
1.
Preparing the Installation
4
2.
Checking the Installation Area
5
3.
Flue Connection & Ventilation Requirements
7
4.
Fresh Air Ducted Inlets
9
5.
Suggested Methods for Heater Suspension
10
6.
Connecting Gas Supply
11
7.
Connecting Electrical Supply
12
ASSEMBLY INSTRUCTIONS
Section
Title
Page
1.
Assembling the Heaters
14
2.
Assembling the Tubes
14
3.
Insert Turbulators
15
4.
Connect Return Bend
15
5.
Fixing the Bracket and U-Bolts
16
6.
Overshield Reflectors
17
7.
Inner Reflectors
18
8.
Outer Canopies
19
9.
Fixing the End Caps
19
10.
Fitting Burner and Fan
20
11.
Fixing of End Moulds
20
12.
Suspension of the Heater
21
3
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1.
Preparing the Installation
Standards
Ambi-Rad Optima heaters must be installed in accordance with the following provisions and regulations.
•
Gas safety (installation and use) regulation 1994.
•
Health and Safety at work act 1974.
•
IEE Regulations.
•
Building standards (Scotland) consolidation regulations.
•
BS5440: PArt 1, BS6891:1988
BS6896: 1991, BS6501: Part 1 1991
BS6500:1975
And any other relevant British standard BS and codes of practice.
•
These instructions are for use in the United Kingdom (GB) and Eire (IE) on natural gas (G20) at 20 mbar and
propane (G31) at 37 mbar supplied pressure.
4
2. Checking the Installation Area
• Make sure the heater is far enough away from combustible materials (see Fig.1).
• There must be 1000mm clearance between any part of the heater and a wall.
• These minimum clearances must be maintained to help with the servicing of the burner.
• Ensure the suspension is sufficiently flexible to allow for thermal expansion (see Fig.5).
• All heaters must slope towards the U-bend approximately 25mm.
E
B
D
D
C
E
G
Figure 1
TABLE 1
BURNER MODEL
16-20
21-25
26-28
29-33
34-35
36-38
11-15
SE
400
100
1490
520
100
1200
400
100
1675
580
100
1400
400
100
1820
500
200
1500
400
100
2060
550
200
1650
400
100
2160
630
200
1760
400
100
2300
730
200
1910
DISTANCE FROM COMBUSTIBLES mm
(50°C rise in temperature above ambient of a black surface)
Above Fan
Above Canopy
Below Reflector Edge
Horizontally to Side
Above Canopy (inclined mounting)
Below Reflector Edge (inclined mounting)
5
DIM.A
DIM.B
DIM.C
DIM.D
DIM.B
DIM.C
400
100
1300
450
100
1000
J
D
C
B
E
A
Figure 2
F
G
E
B
H
A
D
Figure 2a
A
B
C
D
E
F
G
H
J
Side Wall
Canopy
Induced Draught Fan
Suspension Bracket
Burner
Burner Lid
Obstacle above heater
End Moulding
73580 Type Fan - Dim.80mm
76634 Type Fan - Dim.85mm
6
3. Flue Connection and Ventilation Requirements
Optima heaters can be flued to atmosphere or remain unflued providing that the air supply and
ventilation requirements within the building are complied to BS6896:1991. Also due consideration
must be given to the possibilities of condensation forming on cold surfaces and glazing when using an
unflued heater.
Unflued Installation
When installing the heaters unflued, ventilation requirements can be met by the following means:
• Natural Ventilation
• Forced Ventilation
Natural Ventilation
Apertures must be fitted at high and low level with a maximum vertical distance of 3m between them.
• For High and Low level ventilation - where air change rate is less than 33m3/h per kW of total rated input of the
heaters installed an aperture sized to the following criteria.
• 1.4cm2 for each 1m3h per kW below 33m3 per kW; or an aperture 52cm2/kW of total rated input of heaters.
Natural Ventilation
• Where heat input is up to and including 60kW - ventilation should be 4.5cm2/kW of total rated input of the
heaters.
• Where heat input is over 60kW - ventilation should be 270cm2 plus 2.25cm2/kW in excess of the 60kW total rated
input of the heater.
Where apertures are unable to be installed for natural ventilation, ventilation needs to be supplied by
means of a fan or blower to the following standard:
• Ensure minimum proven air flow is 33m3/h per kW of total rated input of the heaters.
• For more detailed information please contact Ambi-Rad’s technical department.
If the heater is installed without a flue ensure that combustion gases do not impinge on any surrounding
combustible materials or glazing. (see Table 1). The maximum permitted temperature rise for such material is
50°C (Ref.BS7186).1989
For detailed information please refer to section 7 BS6896:1991, Installation of Gas Fired Overhead Radiant
Heaters for Industrial and Commercial Heating (2nd and 3rd family gases).
Flued Installation
(See Fig.3)
• When Optima heaters are installed with a flue, a down draft diverter (B) must be fitted to the fan exit by means of
screws and clamp plates provided. (This is supplied as an optional extra by the manufacturer).
• This diverter is designed to accept a 125mm (5in) nominal bore propriety twin wall metal flue pipe (A) which complies
with BS715.
• Specifically for horticulture or green house applications where combustion gases can do harm, a square to round
adaptor is fitted (E).
• Fit to the outlet of the fan by means of the clamp plates and screws provided (D).
• The joints should be sealed with heat resistant caulking and faced off with fire cement.
7
If single wall metal flue piping complying with BS715 1993 is used then an adaptor will be required.
A flue pipe should always be adequately supported at regular intervals from the building structure and terminated
externally with a British Gas tested and certified terminal.
The maximum flue length is 9m (30ft) and the maximum number of bends is 2.
All connections in the flue must be properly sealed.
E
B
D
D
C
FLUE INSTALLATION WITHOUT DOWN DRAUGHT DIVERTER
FLUE INSTALLATION WITH DOWN DRAUGHT DIVERTER
A
Figure 3
A
B
C
D
E
125mm Bore Twin Wall Flue
Down Draught Diverter
Fan
Clamp Plate Screws
Square to Round Adaptor
8
4. Fresh Air Ducted Inlets
A ducted fresh air supply must be provided to the burner when Optima heaters are installed in locations
where there is air born dust or where there is a polluted atmosphere e.g chlorinated vapours, process dust,
foundry environments etc.
How to fit a Fresh Air Supply
(See Fig.4)
• Remove existing air intake grill from burner.
• Fit ducted air adaptor (D) to air inlet flange on the rear of the air intake chamber using the 2 captivated screws (G).
• Attach 100mm Ø flexible duct (C) to the ducted air adaptor (D) using the jubilee clip (B).
• Attach main 100mm Ø supply duct (A) to free end of flexible duct (C) with jubilee clip (B)
Figure 4
A
B
C
D
E
F
G
9
Supply Duct - 100mm Ø
Jubilee Clip - 100mm Ø
Flexible Duct
Ducted Air Adaptor
Burner
End Moulding
Set Pins M5 x 60
5. Suggested Methods for Heater Suspension
Attachment of the support chains to the support brackets should be made using speedlinks. Should drop
rods be used a closed loop should attach the rod to the support bracket.
Due Allowance must be made for thermal expansion of the heater.
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 and to promote free
movement due to linear expansion.
In the event of suitable roof steel work not being available additional steel work should be fitted to enable
vertical hangers to be used for suspending heaters.
If there are any doubts as to the strength or suitability of roof steel work to which the heaters are to be
suspended please refer to the consultant, architect, or owner of the building.
15° max
D
E
45° max
45° max
B
C
C
C
A
C
Figure 5
A
B
C
D
E
Speedlink
Shackle
Drop Rod with Formed Hook
Equal and opposite chain support when angle of inclination is greater than 15°
Vertical chain support when angle of inclination is less than 15°
10
6. Connecting Gas Supply
(See Fig.6)
Gas connection is made by using a flexible metallic hose (F), tested and certified BS6501:Part1,1991.
• The connection is made to the 1/2” BSP male gas inlet connection on the burner assembly.
• The gas supply pipe (D) must terminate at each burner with the service cock (E).
• The gas union (G) must be fitted at each burner end between the service cock (E) and the burner gas inlet
connection.
• It is necessary to form an expansion loop with the flexible metallic hose (F) to provide for linear thermal
expansion of the heating system.
Do not over bend the flexible hose. Elbows must be fitted to eliminate sharp bends near the end fittings.
It must be in line without torsion or twisting.
Jointing compound resistant to the action of liquid petroleum gas and natural gas should be used on all pipe
threads.
Under no circumstances should the gas controls of the burner be subjected to more than 50 mbar
(20in.w.g) otherwise rupture of the control gas diaphragms and other damage will result.
A
B
C
D
E
F
G
H
J
Figure 6
11
End Moulding
Canopy
Suspension Bracket
Mains Gas Supply Pipe
Service Cock
Flexible Gas Hose
Gas Union
90° Elbow
Mains Lead
7. Connecting Electrical Supply
(See Fig.7)
Each component carrying an electrical supply must be earthed.
• A 230 volt 50 Hz single phase supply is required.
• The electrical connection to the burners is made by means of 3 pin plug power connector.
Live, neutral and earth connection should be made via a flexible supply cable to the power isolator and
routed clear of the heater. The power isolator should be no further than 1m from the heater.
The flexible cable should be 0.5mmØ. the current rating per burner is 0.55 amp (inductive). each burner
must be fused externally at 3 amp. All electrical work should be carried out to IEE Standards by a
competent electrician.
All controls and switch gear must be rated to handle the total inductive load of the circuit they control.
For large installations the use of relays or contactors should be considered. The method of connection to
the electrical supply must ensure complete isolation and should be made via a fused double pole isolator,
having contact separation of at least 3mm in all poles and supplying the appliance only. Alternatively
connection may be made via a 3 pin plug and switch shuttered socket both compiling with the
requirements with BS1365.
Typical External wiring
Typical Internal wiring
Figure 7
12
13
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S
1. Assembling the Heaters
Assembly - Stages - Check List
The following are the key stages when assembling a 2 or 3 module Optima heater.
• Tube assembly
• Insertion of turbulators
• Fixing the return bend
• Positioning the bracket
• Fixing the U-bolts
• Fixing the overshield reflectors
• Assembling the inner reflectors
• Assembling the outer canopies
• Fixing the end caps
• Fitting the burner and fan
• Fixing the end mouldings
2. Assembling the Tubes
1.
2.
Support radiant tubes on blocks or trestles.
Assemble the 2 sections of the stainless steel firing leg (A) and (H) by means of pins (J). Ensure pins (J)
are located in holes in the end of the first tube (A).
Note:
Do not fully tighten pins (J) but fully tighten lock nuts (K).
H
K
J
A
14
3. Insert Turbulators
1.
Insert relevant turbulators depending upon the heater model.
Heater Model
Turbulators
Insert at Location
SE 11-15 UT
2 Module
2 x 860mm
1 x 2600mm
(1) and (2)
(3)
SE 16-20 UT
2 Module
1 x 976mm
2 x 2600mm
(1)
(2) and (3)
SE 21-25 UT
2 Module
2 x 860mm
1 x 2600mm
(1) and (2)
(3)
SE 26-35 UT
3 Module
1 x 976mm
(3)
SE 36-38 UT
3 Module
1 x 976mm
2 x 2600mm
(1)
(2) and (3)
4. Connect Return Bend
1.
Connect return bend (C) on to the tubes (H) and (G) wit the U-bend clamping bolts on top. (Fig 9)
2.
Ensure the fixing pins on the heater tubes (for overshield location) are vertical.
3.
Tighten the U-bend clamping bolts securely taking care not to over tighten.
15
2 Module Heater
B3
Location 1
C
O
H
B2
Location 2
A
B1
Location 3
3 Module Heater
C
Location 1
B4
B3
O
H
Location 2
B2
G
A
B1
Location 3
U
R
Figure 9
16
5. Fixing the bracket and U-bolts
1.
Slide the suspension bracket along the tubes into position (as shown in Fig 14) taking care not to
damage the paint finish.
2.
Eight U-bolts are supplied with the heater; two U-bolts are stainless steel and six are zinc plated. The
two stainless steel U-bolts (M) are identified by having lock nut (L) and fixing nuts pre-fitted to each.
3.
The stainless steel U-bolts are fitted to the firing tube (A) on brackets B1 and B2.
Note:
A 3mm distance must be provided around the firing tube to allow thermal expansion on the 1st and 2nd
stainless steel U-bolt.
M
M
A
A
L
L
B1
2 Module Units
L
L
B1 & B2
3 Module Units
4. Position the four suspension brackets along
the tube sets in the following intervals. (see
Fig.14)
4. Position the four suspension brackets along
the tube sets in the following intervals. (see
Fig.14)
• 1st Bracket: (B1) 155mm is from the beginning of
the tube with a loose fitting stainless steel U-bolt on
the firing leg. Tighten the return leg U-bolt to
maintain this position.
• 1st Bracket: (B1) 155mm is from the beginning of
the tube with a loose fitting stainless steel U-bolt on
the firing leg. Tighten the return leg U-bolt to
maintain this position.
• 2nd Bracket: (B2) 1790mm from the 1st bracket.
Tighten both U-bolts to maintain this position.
• 2nd Bracket: (B2) 1785mm from the 1st bracket
with a loose fitting stainless steel U-bolt on the firing
leg. Tighten the return leg U-bolt to maintain this
position.
• 3rd Bracket: (B3) 1430mm from the 2nd bracket.
Tighten both U-bolts to maintain this position.
• 3rd Bracket: (B3) 1795mm from the 2nd bracket.
Tighten both U-bolts to maintain this position.
• 4th Bracket (B4) 1370mm from the 3rd bracket.
Tighten both U-bolts to maintain this position.
17
2 Module Heater
W
1430 Bracket CRS
1790 Bracket CRS
155 CRS
V
W
3 Module Heater
1370 Bracket CRS
1795 Bracket CRS
1785 Bracket CRS
155 CRS
V
W
Figure 14
18
6. Overshield Reflectors
1.
To attach the overshields on the heater tubes, first place washers (WS) onto fixing pins (N) before placing
overshields (O) onto fixing pins. Place further washers (WS) onto fixing pins before securing with split
pins (P).
2.
Open the ends of the split pins after inserting them through the fixing pins (N).
P
WS
O
WS
N
19
7. Inner Reflectors
2 Module Units
3 Module Units
1. Place the 1st and 2nd inner reflectors (R) on the
heater by sliding the reflectors between the tubes and
the brackets. (Fig.9)
1. Place the 1st, 2nd and 3rd inner reflectors (R) on the
heater by sliding the reflectors between the tubes and
the brackets. (Fig.9)
2. Overlap each reflector by 15mm and bolt together i.e.
utilising the two slotted holes on the sides of each
reflector and the single hole in the middle of the
leading edge of the reflector. Bolt the 1st reflector to
the 2nd reflector.
2. Overlap each reflector by 15mm and bolt together i.e.
utilising the two slotted holes on the sides of each
reflector and the single hole in the middle of the
leading edge of the reflector. Bolt the 1st reflector to
the 2nd reflector to the 3rd reflector.
Make sure that the 1st reflector sits on top of the
2nd.
Make sure that the 2nd reflector sits on top of the
1st and 3rd reflectors.
3. Insert reflector location bolts (X) through each side of the first bracket. the end of the bolts locate into the
corresponding holes in the inner reflector.
4. 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.
20
8. Outer Canopies
2 Module Units
3 Module Units
The outer canopies are made up of 4 identical half
covers (U) which engage into the side of the 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 following method;
The outer canopies are made up of 6 identical half
covers (U) which engage into the side of the inner
reflectors and join at the centre by way of a closing
plate (Y) which holds the two halves together. Install
the outer canopies using the following method;
1. Slide on the two halves to cover the 1st section of the
heaters and fit closing plates to each end (Y) to the
second set of canopies.
1. Slide on the two halves to cover the centre section of
the heaters and fit closing plates to each end (Y).
2. Slide on two more outer canopies.
3. Stop short of the canopies already fitted and fit closing
plates (Y).
3. Stop short of the canopies already fitted and fit closing
plates (Y).
4. Insert the ends of the second set of canopies inside the
first set at the central joint.
5. A slot (Z) 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.(see Fig.13)
2. Slide on two more outer canopies.
4. Insert the ends of the second set of canopies inside the
first set at the central joint.
5. A slot (Z) 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.
6. Repeat the procedure for 3rd set of outer canopies.
9. Fixing the End Caps
1.
Insert the end cap (D1 and D2) into the end of the outer canopies making sure that the end cap engages
inside the inner reflector before inserting eight securing screws and covering washers.
D1
D2
Figure 10
21
Figure 11
10. Fitting Burner and Fan
1.
Attach the burner and fan assembly and tighten securely by the use of a 4mm allen key.
Note:
The fan is fitted to the end of the black radiant tube and secured using the grub screw on the support
spinning.
Ensure fan discharges horizontally away from the burner if the system is unflued and vertically
upwards if the system is to be flued or if end mouldings are to be fitted (see Fig.12 and section 2 of
general instructions.
Figure 12
11. Fixing of End Mouldings
1.
If end mouldings have been ordered (optional item) fit the end mouldings with the screws provided to
the holes in top of the canopy/end mouldings.
When installing end mouldings with an Optima heater, the fan outlet must be positioned vertically upwards.
A flue guard is supplied to prevent ingress of foreign bodies into the fan when the heater is not working.
G
F
E
B
H
A
D
22
12. Suspension of the Heater
1.
The heater must be suspended on all 3 of the brackets. On all 4 brackets if it is a 3 module heater (see
section 5 in general instructions).
All U-tube heaters must be suspended with U-bend of the heater 25mm lower than the burner end.
This procedure has been based on floor assembly of the heaters. The procedure can be undertaken in
the roof area at the installing contractor’s risk.
23
Ambi-Rad Limited Fens Pool Avenue
Brierley Hill West Midlands
DY5 1QA United Kingdom
Telephone 01384 489700
Facsimile 01384 489707
Email info@ambirad.co.uk
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/SE/053/0506
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