Ambirad VISION VSO Assembly instructions

1
ASSEMBLY, INSTALLATION & SERVICING MANUAL
FOR AMBIRAD VISION®VSO & VSXO
RANGE OF RADIANT TUBE HEATERS
INDEX Section
Introduction and Document Index
Installation Requirements-------------------------------------------------1
Assembly Instructions------------------------------------------------------2
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 6896:2005 (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.

2

3
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
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
1.11 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
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.

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1.1 Health and Safety
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
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 6896:2005
(Industrial & Commercial) and any other
relevant British Standards and Codes of
Practice by a qualified installer. Isolate all
electrical supplies to the heater & controller
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.
1.2 Model Definitions
VSOUT = AmbiRad Vision U Tube Unitary
heater with painted induced burner, ID Fan,
aluminised steel reflectors, end caps,
insulation, tube over shields, painted canopies
and optional end covers.
VSOUH = AmbiRad Vision U Tube
Herringbone heater with painted induced
burner, Damper, aluminised steel reflectors,
end caps, insulation, tube over shields, painted
canopies and optional end covers.
VSXO = AmbiRad Vision High efficiency
U Tube heater with forced burner, recuperative
heat exchanger, aluminised steel reflectors,
end caps, insulation, tube over shields, painted
canopies and optional end covers.
1.3 Heater Suspension
See fig 3.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.
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
minimum mounting heights for AmbiRad heaters
are given in the table below.
1.4 Wall Mounting
These radiant tube heaters can be wall mounted
using the appropriate bracket (AmbiRad part no
WMB-13-22-38).
When using the wall mounting brackets the
heater must be inclined at an angle between 30°
and 35°.
U Tube
Heater
Size Required angle Chain length Eyebolt position
15 - 50 30-35° 12 links 1
1. Installation Requirements.
Isolate any electrical supply to the
heater and controller before proceeding.
The heater must be suspended by
ALL of the suspension brackets.
3
.
E
Figure 3.a. Angle Mounting using the Wall
mounting bracket 1
Model
MINIMUM
Mounting Height (m)
Horizontal Inclined / wall
mounted
15 4.4 3.9
20 4.9 4.4
25 5.4 4.7
30 6.3 5.5
35 6.5 5.7
40 6.9 6.0
45 7.3 6.5
50 7.8 6.9

5
Figure 3.b. Recommended Methods of Heater Suspension.
Where chain supports have an
angle of inclination greater
than 15° an equal and opposite
support is recommended.
Vertical suspension chain ideal. Where supports are inclined, maximum recommended angle of inclination is 15°.
Shackle method of attachment. Pin must be tightened by pliers.
Drop rod with formed hook. note. hook or eyebolt must be closed tight.
These angles to be equal and not more than 45°.
15° max.
Vertical or inclined suspension on this plane is acceptable.
*
*
Typical Speedlink attachment.
ON U TUBE VARIANTS THE HEATER SHOULD SLOPE DOWNWARDS TOWARDS THE RETURN
BEND BY APPROX. 10mm FOR BOTH HORIZONTAL AND WALL MOUNTED INSTALLATIONS.

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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
end of the manifold system. (See figure 4a
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.
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 exhaust flue should be adequately
supported from the building structure and
installed in accordance with the British
Standard Code of Practice BS 5440: Part
1:2000 – Installation and maintenance of flues
and ventilation for gas appliances of rated input
not exceeding 70kW net (1st, 2nd and 3rd
family gases)
A condensate trap assembly must be provided
at the end of the manifold system before the
hot gas vacuum fan.
The minimum depth of the condensate
collecting chamber shall be 305mm and the
minimum depth of the condensate drain pipe
‘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.
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
22mm internal diameter. Copper or copper
based alloy shall not be used for condensation
drains. See reference BS 6896:2005.
Condensate drain pipes must be protected
against the effects of freezing.
The Type ‘0’ and Type ‘2’ vacuum fans have
bottom horizontal discharge with rectangular
connections (flanged on the type 0) and must be
mounted in that position by means of the fan
support stool onto a suitable platform or
brackets fixed to the building structure.
For details of the fan outlet fixing holes see
below.
305.0457.0
Figure 4a.
Condensate
Trap Arrangement
Figure 4c. Type ‘O’ Fan Outlet Dimensions
Figure 4d.
Type 2 Fan
Outlet Dimensions
190 213
Figure 4b. Collecting Chamber Arrangement
The manifold must be supported either
side of the flexible coupler.

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For details of fan mounting bracket and fixing
down holes see figure 5.
Figure 4e. Conventional Flue Arrangement
Roof Exit.
Figure 4f. Conventional Flue Arrangement
Wall Exit.
Figure 4g. 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 4h. Typical Low Fan Arrangement
305.0

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Fig 4c/d
Fan Type O Type 2
A 124 80
B 38 35
C 175 174
D 7.1 7
E 209 125
F 153 100
G 42 25
H 239 120
J 340 210
K 332 205
L 363 215
Power (watts) 550 120
Running Current (amps) 2.6 0.8
Voltage 230V 1ph 230V 1ph
Figure 5. Vacuum Fan Mounting Details (Type ‘O’ fan illustrated)
Hole CentersHole Centers

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Figure 6. Typical Herringbone system (VSO shown with optional end covers)
Dos Don’ts
Check for corrosive industrial process in
proposed building - e.g. cleaning, electroplating,
printers using sugar powder etc.
Install system with extra 90° bends without asking
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 4). Fit damper upside down or on it’s side.
Fit expansion joints before fan and at
intermediate points on the herringbone system. Fit damper wrong way round. (see fig20)
Run drains in galvanised steel or plastic pipes.
Follow guide to combined flue heating system.
Check design pressure drop. Run drains in copper or mild steel pipework.
Dos and don'ts of herringbone system

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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 7.a Diagram illustrating the clearance to combustibles (VSXO shown c/w End Covers)
VSXO 20/25 30/35/40
Above Canopy A 100 100
Above Burner / Flued Heat Exchanger B 500 500
To the Sides C 915 1200
Below Tubes D 2330 2330
From Heater Outlet (UNFLUED) E 570 940
End Wall F 390 470
Above Burner / Heater Outlet Unflued B1 700 700
45/50
100
500
700
1525
2330
940
575
F
D
AB
C
E
DIM 'C'
DIM 'D'
DIM 'C'
DIM 'B'

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Figure 7.b Clearance to combustibles Vision Optima Unitary VSO UT
F
D
AB
C
DIM 'C'
DIM 'C'
DIM 'B'
DIM 'C'
VSO UT 15/20/25 30/35/40
Above Canopy A 100 100
Above Burner / Flued Heat Exchanger B 500 500
To the Sides C 915 1200
Below Tubes D 2330 2330
From Heater Outlet (UNFLUED) E 570 940
End Wall F 390 470
Above Burner / Heater Outlet Unflued B1 700 700
45/50
100
500
700
1525
2330
940
575

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Figure 7.c Clearance to combustibles Vision Optima Herringbone VSO UH
F
D
AB
C
DIM 'C'
DIM 'C'
DIM 'B'
DIM 'C'
VSO UH Herringbone 15/20/25 30/35/40
Above Canopy A 100 100
Above Burner / Flued Heat Exchanger B 500 500
To the Sides C 915 1200
Below Tubes D 2330 2330
From Heater Outlet (UNFLUED) E 570 940
End Wall F 390 470
Above Burner / Heater Outlet Unflued B1 700 700
45/50
100
500
700
1525
2330
940
575

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to the heater not to apply excessive turning
force to the internal controls.
A flexible hose is installed to allow safe linear
expansion of the heater without creating undue
stress on the gas supply pipe work. It is
therefore important that a tested and certified
hose assembly made to ISO 10380 2003,
supplied with ½” BSP female cone seat
adapters, is installed as per these instructions.
It is also important to ensure that expansion is
taken up in the body of the flexible hose, and
not on its attachment to the pipe work. The cone
seat adapter supplied on one end of the flexible
gas hose provides a `swivel` action, and must
be fitted on the burner using a ½” BSP barrel
nipple to provide ease of disconnection for
future servicing. This assumes that the heater
and fixed gas supply to the isolating valve have
been installed.
The installation layout described below is
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.
fig.a fig.c
x x
fig.b
1.7 Gas Connection and Supply
Before installation, check that the local
distribution conditions, nature of gas
and pressure, and adjustment of the
appliance are compatible.
A competent or qualified engineer is required to
either install a new gas meter to the service
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
accordance with BS 6896:2005, so that the
supply pressure, as stated in Table 4 will be
achieved. It is the responsibility of the
competent engineer to ensure that other
relevant Standards and Codes of Practice are
complied with in the country of installation.
Pipes of smaller size than the heater inlet gas
connection must not be used. The complete
installation must be tested for soundness as
described in the country of installation.
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
Figure 8. Correct Installation of Flexible Gas Connection
The methods shown in fig.e and fig.f are unacceptable, due to undue stress on the hose & fittings.
fig.e
fig.f
Arrow
denotes direction
of expansion.
fig.d
300 +/- 50mm
50 +/- 20mm

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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 I2H I3P
Gas Type Natural Gas (G20) Propane (G31)
Max Supply Pressure (mbar) 25 45
Min Supply Pressure (mbar) 17 25
Nominal Pressure (mbar) 20 37
Gas Supply Connection R½ ½in BSP Internal Thread
1.8 Electrical Connection
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 6500:2000. The wires in
the mains lead are coloured in accordance with
the following code:
Green & Yellow Earth;
Blue Neutral;
Brown Live
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 9.a Single Phase Wiring

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Figure 9.b Typical VSOUT Induced Unitary Wiring Connections (end covers not shown)
Figure 9.e Typical VSXO Powered burner Wiring Connections (end covers shown)
Figure 10. Internal Burner Wiring Diagram.
Fan plugs
into burner
Fused
Spur
Figure 9.c Typical VSOUH Herringbone Wiring Connections (end covers not shown)
Fused Spur
Fused Spur
Fan plugs
into burner
Figure 9.d Typical VSXO Powered Burner Unitary Wiring Connections (end covers not shown)
Fused Spur
Fan plugs
into burner

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MAIN J.S.T.
YELLOW
GREY
WHITE
FLAME SENSOR
IGNITER
8
7
911
10 12
13
24
BLACK
PINK
WHITE
LAMPS
ON
BURNER
GREY
YELLOW
BLACK
GRN/YEL
BROWN
SOLENOID VALVE
SWITCH
N.C.
N.O.
C.
GREY
EMC FILTER
MAINS INPUT
LN
FAN
N
L
ON
MAINS
BLUE
BLUE
BLUE
BLUE
BLUE
VACUUM
BROWN
13
2
VALVE
J.S.T.
GRN/YLW
BLUE
GREEN/YELLOW
Figure 10. Internal Burner Wiring Diagram.

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1.9 Ventilation Requirements
AmbiRad tube heaters can be operated as
flued or unflued appliances in accordance with
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 (CO2) at positions where the air
will be inhaled does not exceed 0.28%.
BS EN 13410:2001 is a guide to achieving this
requirement.
If the building air change rate exceeds 1.5 per
hour or if the heat input is less than 5W/m³, no
additional ventilation is required.
In addition to the ventilation requirements, con-
sideration needs to be given to the 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 installed to
meet a minimum of 1.5 air changes per hour
using appropriately sized fans and interlocked
with the heaters.
Natural Ventilation
BS EN 13410:2001 should be used to size air
vents to provide adequate ventilation, an
example of this calculation is given below:
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
13410:2001 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
In buildings having an air change rate of less
than 0.5 per hour, additional mechanical or
natural ventilation is required. For detailed
information, please see BS6896:2005 section
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.
1.10 Flue and Combustion Air Inlet -
Options
Induced Burners without Heat Exchangers
Please refer to Figure 12 for options.
Tail Pipe
1 phase 230V
Exhaust Fan
230V 50Hz 13A
Mains Supply
0.75mm²
Screened Cable
Isolator
Sensor
Zone A
Controller
Isolator
Isolator
Isolator
Isolator
Figure 11. Typical VSO UH
Schematic Wiring
Connections

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Option 1 - Figure 12a. Air Inlet Attachments Unitary Herringbone Burners (VSO)
A 127mm (5ins) Twin Wall Flue System
B Fan Adaptor 7177-SUB
C Fan 2501/2507 or 2560
D Optional Ducted Air Intake. VSI-DA
E Air Intake (supplied as standard)
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
Minimum diameter = 100mm
Maximum no of bends = 2
Maximum flue length = 9.5m @ Ø125mm
Maximum no of bends = 2
All flues must terminate vertically.
For further information on flue runs, please refer
to BS 5440 pt.1 2000
For non-flued installations, delete items A and
B and rotate fan outlet to the HORIZONTAL
position away from the burner.
Products of Combustion
Products of combustionFiring tube
Ducted Air Intake
D
E A
B
C

19
Option 1 - Figure 12b. Air Inlet Attachments Induced Herringbone Burners (VSO)
A Induced Burner
B Air Intake (supplied as standard)
C Optional Ducted Air Intake. (see
notes)
D Damper assembly
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
Minimum diameter = 100mm
Maximum no of bends = 2
B
Products of Combustion
Ducted Air Intake
Firing tube
C
D
A

20
Ventilation requirements are as detailed in
section 1.9
Option 2 - Figure 12c. Forced Burner with Heat Exchanger (VSXO Standard Flue)
For flued products of combustion and no ducted air
Products of combustion
Air
Inlet
F
H
G
K
L
G
G
E
J
Products of combustion
Firing
tube
E Forced Burner
F Heat Exchanger
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
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
Minimum diameter = 100mm
Maximum no of bends = 2
Maximum flue length = 9.5m @ Ø125mm
Maximum no of bends = 2
All flues must terminate vertically.
For further information on flue runs, please refer
to BS 5440 pt.1 2000