Ambirad Vision VPLUS HL120V Instruction manual

Doc No 700105 (06-15), Page
VPLUS HL OWNERS MANUAL
INSTALLATION / OPERATION / MAINTENANCE
Applies to: Model VPLUS HL120V 60Hz
Gas-Fired, Tubular, Radiant,
Low-Intensity Infrared Heater
Part # 700105
WARNING: Improper installation, adjustment,
alteration, service or maintenance can cause
property damage, injury or death. Read the
installation, operating and maintenance instructions
thoroughly before installing or servicing this
Vision Range
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Doc No 700105 (06-15), Page 2
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.
PLEASE READ this document prior to
installation to familiarize yourself with the
components and tools you require at the various
stages of assembly.
All dimensions shown are in inches unless
otherwise stated.
The manufacturer reserves the right to alter
specifications without prior notice.
Welcome to the new range of powered HiLo
infra-red heaters. Local regulations may vary
and it is the installer’s responsibility to ensure
that such regulations are satisfied.
All installation, assembly, commissioning and
service procedures must be carried out by
suitable qualified competent persons and
conform with local building codes, or in the
absence of local codes, with the National Fuel
Gas Code ANSI Z223.1/NFPA 54 or the
National Gas and Propane Installation Code
CSA B149.1.
When assembling, installing, commissioning
codes, with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54 or the Natural Gas
and Propane Installation Code, CSA
B149.1.
D. The unit shall be electrically grounded in
accordance with National Electric Code
ANSI/NFPA 70 and Canadian Electrical
Code CSA C22.1.
E. The heater may be installed in aircraft
hangars in accordance with the Standard
for Aircraft Hangars, ANSI/NFPA 409 and
in automotive garages when installed in
1.1 Health and Safety
A. Heater is intended for heating
non-residential indoor spaces and should
only be installed where flammable gases
or vapors are not generally present.
B. Heaters may be suspended either
horizontal or at any angle. See section
1.3 for clearance dimensions.
C. The installation must conform with local
building codes or, in the absence of local
1 Installation Requirements
1.1 Health & Safety
1.2 Heater Suspension
1.3 Clearance to Combustibles
1.4 Gas Connection & Supply Details
1.5 Electrical Connections
1.6 Ventilation Requirements
1.6.1 Unvented Units
1.6.2 Vertical Venting
1.6.3 Horizontal Venting
1.7 Fresh Air Intake
1.8 Technical Details
2 Assembly Instructions
2.1 Tools Required
2.2 Assembly Notes
2.2.1 Tubes
2.2.2 Turbulator Strips and Burner Inserts
2.2.3 Brackets
2.2.4 Couplers
2.2.5 Reflectors
2.2.6 End Caps (optional)
2.2.7 Bends (where required)
2.2.8 Burner/Fan Assembly
2.2.9 Detailed Assembly Drawings
3 Start Up Instructions
3.1 Tools Required
3.2 Start up procedure
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
4.7 Radiant Tube Servicing
4.8 Reflector Servicing
4.9 Cleaning of Vent
4.10 Re-commissioning after Service
5 Troubleshooting Guide
6 Replacing Parts
6.1 Burner Controller Replacement
6.2 Air Pressure Switch Replacement
6.3 Gas Valve Replacement
7 User and Operating Instructions
7.1 To Start Heater
7.2 To Switch Off Heater
7.3 Servicing
Introduction.
Document Index.
1. Installation Requirements.
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Doc No 700105 (06-15), Page 3
accordance with the Standard for
Parking Structures, ANSI/NFPA 88A, or
the Standard for Repair Garages, ANSI/
NFPA 88B, or the Canadian Natural Gas
and Propane Installation Code, CSA
B149.1, and are so marked.
Ensure that minimum clearances will be
maintained to vehicles parked below the
heater.
F The standard heaters are approved for
installations between 0 - 2000ft (0 - 610m)
for the US and 0 - 4500 ft (1370m) for
Canada. Conversion kits are available on
installations above these heights in the
USA.
G. Massachusetts Requirement: If the
heater is being installed in the
Commonwealth of Massachusetts, this unit
must be installed by a licensed plumber or
licenced gas fitter.
1.2 Heater Suspension
Attachment to the heater support lugs should
be made by D shackle. The hanging
attachments to overhead steelwork etc. must
be purpose made to sound engineering practice
or supplied by others. 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.
These methods are illustrated in Figure 1. 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.
It is recommended that the heater is raised to its
final position once the assembly of the tube/
bracket/reflector has been completed. Longer
tube assemblies may be raised in more than
one sub-assembly with final tube connection
made in the air.
Ensure that the installer uses the burner roof
support mounting bracket when suspending the
heater. This is situated on the front of the
burner. When packed the bracket is reversed
and must be turned to its correct state for
mounting. (ref page 18)
WARNING:
If not installed, operated and maintained in accordance with the manufacturer’s
instructions, this product could expose you to substances in fuel or from fuel combustion
which are known to the state of California to cause cancer, birth defects or other
reproductive harm.
CHAIN 55° SUSPENSION
NOTE.
'S' HOOKS ARE TO
BE CLOSED UP
AFTER ASSEMBLY
EXHAUST
END
BURNER
END
U TUBE VARIANTS
SUITABLE CHAIN
WORKING LOAD
LIMIT 100LB
Figure 1. Recommended Methods of Heater Suspension.
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Doc No 700105 (06-15), Page 4
1/2
”
UNVENTED
VENTED
1/2”
1.3 Clearance to Combustibles.
Minimum clearance to combustibles are shown in Table 1 below.
IMPORTANT:
The stated clearance to combustibles represents a surface temperature of 90°F (50°C) above room
temperature. Building material with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply,
etc.) may be subject to degradation at lower temperatures. It is the installer’s responsibility to assure
that adjacent materials are protected from degradation.
Building material with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.) may be
subject to degradation at lower temperatures.
It is the installer’s responsibility to assure that adjacent materials are protected from degradation.
Table 1 Clearance to Combustibles, inches (cm)
MODEL A A1 / A2 B B1 C1 C2 C3 D1 D2 E
40 49
(125)
15° = 48 (122)
25° = 45 (115)
35° = 41 (105)
45° = 35 (89)
55° = 29 (74)
24
(61)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
60 74
(188)
29
(74)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
80 74
(188)
29
(74)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
12
(31)
12
(31)
100 74
(188)
32
(82)
41
(105)
20 (51) /
10* (26)*
8
(21)
22
(56)
8
(21)
16
(41)
12
(31)
125 74
(188)
39
(99)
47
(120)
20 (51) /
10* (26)*
8
(21)
22
(56)
20
(51)
18
(46)
12
(31)
150 74
(188)
39
(99)
48
(122)
20 (51) /
10* (26)*
8
(21)
22
(56)
20
(51)
18
(46)
12
(31)
170 86
(219)
15° = 82 (209)
25° = 78 (199)
35° = 71 (181)
45° = 61 (155)
55° = 50 (127)
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(31)
200 86
(219)
48
(122)
48
(122)
20 (51) /
10* (26)*
11
(28)
22
(56)
20
(51)
20
(51)
12
(31)
15° = 72 (183)
25° = 68 (173)
35° = 61 (155)
45° = 53 (135)
55° = 43 (110)
Minimum clearance from the heater must be maintained from vehicles
parked below heater. In all situations, clearances to combustibles must be
maintained. Signs should be posted in storage areas to specify maximum stacking height to
maintain required clearance to combustibles. Such signs must either be posted adjacent to
the heater thermostats or in the absence of such thermostats in a conspicuous location.
Refer to mounting clearance tables.
WARNING:
* distance with end caps fitted.
ON VENTED HEATERS, THE HEATER SHOULD SLOPE DOWNWARDS AWAY FROM
THE BURNER AND ON UNVENTED HEATERS SHOULD SLOPE DOWNWARDS
TOWARDS BURNER BY APPROX. ½” FOR HORIZONTAL INSTALLATIONS AS SHOWN
BELOW (DIAGRAMS EXAGGERATED FOR CLARITY)
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Doc No 700105 (06-15), Page 5
C2
C1
A
B1
B
B
A1
E
D2
.
D1
Ensure that there is adequate
provision in the building for
combustion and ventilation air supply.
Installation must meet minimum
requirements and applicable codes.
Burner end.
Outlet end. Angled view.
End view.
C3
Below
heater
Side
vented
Side
unvented
End
unvented
Above outlet
unvented
Above
Reflector
Above
Burner
Service
distance
Return end on
U tube heater
WARNING!
0° to 55°
A2
C1
E
Above
Burner
Service
distance
Figure 2 Clearance to Combustibles (Standard indoor reflectors)..
The minimum clearances to combustible materials are given in Table 1 These minimum
distances MUST be adhered to at all times. Adequate clearance MUST be provided around air
openings into the combustion chamber and there MUST be suitable clearance for accessibility and
for combustion / ventilating air supplies.
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Doc No 700105 (06-15), Page 6
1.4 Gas Connection and Supply
The gas connection on the heater is ½” N.P.T
internal thread.
Injector sizes and manifold pressure for the
burners are shown in the table 3. The gas
supply piping and connections must be installed
so that the minimum pressure stated is
achieved.
A gas shut off valve and union should be fitted
in the gas supply line close to the heater and a
⅛” N.P.T plugged tapping, accessible for test
gauge connection, provided immediately
upstream of the appliance gas inlet.
It is essential to provide some flexibility in the
final gas connection by use of an approved
flexible gas connector. (See Fig 4.)
Take care when making a gas connection
to the heater not to apply excessive turning
force to the internal controls.
Care must be taken to observe the minimum
pipe bend diameter (minimum 10” (254mm),
maximum 14”(356mm) & pipe expansion
distance (minimum 1⅛” (25.4mm), maximum
3¾”(95mm).
The correct installation as shown will allow
for approx 4” of movement due to
expansion.
WARNING: Before installation, check
that the local distribution conditions,
nature of gas and pressure, and adjustment
of the appliance are compatible.
Figure 3. Correct orientation of Ball Valve
Gas Flow
Gas Flow
Figure 4. Correct Installation of Flexible
Gas Connection
Table 2 HOSE SIZE PART No.
3/4” A4129
1/2” A4128
* Connector must be certified for use on a radiant tube
type infrared heater and must comply with Standard for
Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 or
with the Standard for Elastomeric Composite Hose and
Hose Couplings for Conducting Propane and Natural Gas,
CAN/CGA 8.1.
For heaters up to 150,000Btu/h, ½” ID x 24” long
For heaters 150,000Btu/h and above, ¾” ID x 36” long
NOTE: For Canada all heaters MUST use a hose 36” long
(See Table 3)
WARNING: FIRE OR EXPLOSION HAZARD - It is essential to provide some flexibility in
the final gas line connection by use of an approved flexible connector as shown in the
drawings. Expansion of the radiant pipe occurs with each firing cycle causing the burner to
move with respect to the gas line. This can result in a gas leak producing an unsafe
condition.
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Doc No 700105 (06-15), Page 7
Table 3 Gas Supply Pressures
Gas Type Natural Gas LP/Propane Gas
Min Required Gas Pressure (in W.C) 7.0 11.0
Max Supply Pressure (in W.C) 14.0 14.0
Gas Supply Connection ½” N.P.T thread
CONNECTOR MUST BE INSTALLED IN A “U” CONFIGURATION. FOR HEATERS UP
TO 150,000 BTU/H, A 24” LONG CONNECTOR OF AT LEAST ½” ID MUST BE USED.
FOR HEATERS ABOVE 150,000 BTU/H, A 36” LONG CONNECTOR OF AT LEAST ¾”
NOMINAL ID MUST BE USED.
F2
F1
R
C
W1
W2
24V AC
Terminals
(120V AC Fan
Terminals)
120V AC
Supply
24V AC 2-Stage
Thermostat (Ext.)
RC
W1 W2
Burner 1
E
N
L
N
E
BL
BK
KEY:
BK-BLACK
BL-BLUE
R-RED
O-ORANGE
G-GREEN
W-WHITE
R
O
BK
G
W
Notes:
Use 18/4 class 2 thermostat cable
between heater and thermostat.
Max. length @ 18 Awg (0.8mm²) =
100ft.
Only one burner can operate from
one thermostat as supplied.
When servicing heaters ensure
the electricity supply is isolated
from the mains supply.
120V AC supply is still present at
each burner when the thermostat
is switched off.
1.5 Electrical Connections
This appliance must be electrically grounded
Supply 120V 60Hz single phase.
Standard heater 0.16HP.
Current rating (inductive):
1.8 amp max (models 40 - 150)
1.0 amp max (models 170 & 200)
Fuse: external 3 amp.
Important: All electrical work should be done by a
qualified electrician in strict accordance with the
National Electrical Code ANSI/NFPA 70 or
Canadian Codes CSA C22.1.
The electrical supply to
the heater is by three
wires: hot (Live), neutral
and ground connections.
Install in accordance with
all state & local codes.
Where alternative
manufacturers controls
are used, please refer to
their instructions for their
installation details.
WARNING: Before making electrical
connections, switch OFF the main
electrical disconnect. There may be more
than one disconnect switch. Lock out
and tag switch with a suitable warning
label. Electrical shock can cause
personal injury or death.
Figure 5. External Wiring Schematic
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Doc No 700105 (06-15), Page 8
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
with wiring material having a temperature rating of at least 220°F/105°C
LN
E
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
E
Gas Valve
C
M
HI
NOTES:-
Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner.
Additional wiring is required to install an optional extra thermostat and / or time clock.
Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C
Pressure Switch
120V/24VAC 60Hz
Transformer
Power ON (red)
BK
R
Y
O
BR
GR
BL
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
R - RED
W - WHITE
Y - YELLOW
O - ORANGE
P - PURPLE
BR
Y
P
YY
R
W
G
BK
W
G
BL BR
PGR
P
GR
K
BR
W
BK
LNE
120V AC
Supply
BK
F1 NEF2
120V AC Fan
Terminals
High Fire
KGR
24V AC
RELAY
21
1424
11
A2
1222
A1
High Fire
Relay
COIL
NC
NO
COM
CW2W1 R
24V AC Stat
Terminals
K
O
BL
BR
Low Fire
(amber)
CW2W1 R
24V Two stage
Thermostat
R
W
G
BK
W
G
BK
BL
R
BK
R
K
O
BL
BR
E
Figure 6a. Internal Burner Wiring Diagram.
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Doc No 700105 (06-15), Page 9
1.5.1 Multiple burner configurations (Master
& Slave) via Optional Relay.
Refer to figure 6b and 6d.
Multiple burners can be controlled via one main
burner. In this scenario the main burner is
knows as the ‘Master’ and any additional
burners are known as ‘Slaves’.
The external two stage thermostat is connected
to the Master burner and powered via the inbuilt
transformer. The total burner load for the Master
is 20VA. Each additional ‘Slave’ burner is 1.6VA
The Thermostat chosen to control the multiple
heaters must not have a power requirement
exceeding the spare capacity as shown in the
examples below.
CONFIGURATION TOTAL BURNER LOAD SPARE FOR THERMOSTAT
Master PLUS 1 Slave 21.6VA 18.4VA
Master PLUS 3 Slaves 24.8VA 15.2VA
Master PLUS 5 Slaves 28.0VA 12.0VA
Master PLUS 7 Slaves 31.3VA 8.8VA
Figure 6b. Wiring schematic. Multiple Burners Master and Slave.
Figure 6c. Wiring schematic. Multiple Burners via independently powered Relay.
Supply circuit
120V 60Hz 1 Ph
L2
L1 (HOT)
GND
MASTER
BURNER
THERMOSTAT
SLAVE
BURNER
SLAVE
BURNER
SLAVE
BURNER
LEN
R
C
W1
W2 W1 W2 W1 W2 W1 W2
LENLENLEN
R
C
W1
W2
24VAC 60Hz 1 Ph Hi/Lo circuit
1.5.2 Multiple burner configuration via
independently powered two stage
thermostats. Refer to figures 6c and 6d.
Note: If the thermostat has an independent
power supply, all burners in the zone to be
controlled MUST be Slave burners.
The maximum number of Slave burners per
thermostat is dependent on the maximum
power output of the thermostat selected.
Each ‘Slave’ burner is rated at 1.6VA 24VAC
60Hz.
The external two stage thermostat is powered
via its own power supply and must output to
each Slave burner - 24VAC for low fire to
terminal W1 and 24VAC for hi fire to both
terminals W1 and W2
Refer to thermostat manufactures literature for
details.
Supply Circuit
(by others)
Supply circuit
120V 60Hz 1 Ph
L2
L1 (HOT)
GND
SLAVE
BURNER
THERMOSTAT
SLAVE
BURNER
SLAVE
BURNER
SLAVE
BURNER
LEN
W1
W2
W1 W2 W1 W2 W1 W2
LENLENLEN
Low fire output
Hi fire output
24VAC 60Hz 1 Ph Hi/Lo circuit
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Doc No 700105 (06-15), Page 10
E
L1
Gas Control
MV
X
C
COM
W1
PS0
PS1
IND
R
E
Gas Valve
C
M
HI
NOTES:-
Power On light is permanently illuminated when 120V / 60 Hz AC external supply is connected to burner.
Additional wiring is required to install an optional extra thermostat and / or time clock.
Wire specification:- 18 AWG (1.0mm²), Tri-rated, 105°C
Pressure Switch
120V/24VAC 60Hz
Transformer
BK
R
Y
O
BR
GR
BL
KEY:
BL - BLUE
BK - BLACK
BR - BROWN
GR - GREY
G - GREEN
K - PINK
R - RED
W - WHITE
Y - YELLOW
O - ORANGE
P - PURPLE
BR
Y
P
YY
R
W
G
BK
W
G
P
GR
K
BR
W
BK
LNE
120V AC
Supply
BK
F1 NEF2
120V AC Fan
Terminals
24V AC
RELAY
21
1424
11
A2
1222
A1
High Fire
Relay
COIL
NC
NO
COM
CW2W1 R
24V AC Stat
Terminals
K
CW2W1 R
24V Two stage
Thermostat
R
W
G
BK
W
G
BK
BL
R
BK
R
K
O
E
BL
24V AC
RELAY
21
1424
11
A2
1222
A1
COIL
NO
BL
O
COM
O
BL
BR
R
OPTIONAL RELAY WIRING
Relay mini harness leads
5A connector
BR
LN
Power ON (red)
BL BR
PGR
High Fire
KGR
Low Fire
(amber)
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
with wiring material having a temperature rating of at least 220°F/105°C
Figure 6d. Internal Slave Burner Wiring/External Schematic Diagram with Optional Relay.
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