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ADL Manual - Space-Ray
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1. nE Ca Side View TI I 8 u View Above shows typical arrangement for flue to the back of the heater Fig 35 Form 44201100 48 Sept 2010 RevA 16 4 TypeCa2 The following figure shows the typical arrangements for concentric vertical flues see Table 18 for 90 bend equivalent lengths The bends shown in the illustrations connecting the combustion air intake to the concentric ducts is calculated into the overall length For example a system with one additional 150 100mm concentric 90 bend can be installed with 1m 100mm flue single pipe and the combustion air single pipe as shown with 5 5m of 150 100mm straight concentric flue 8m 2 5m from Table 18 i J Components O Nr Supplier Description E 1 M amp G Roof Terminal 150 100mm 2 M amp G Concentric vent 150 100mm 3 M amp G Flue Single pipe 100mm Max 8m 4 M am
2. Fresh air and flue horizontal B22 Fresh air and flue vertical Flue horizontal B22 Flue vertical C52 Fresh air amp Flue horizontal in different pressure C52 Fresh air vertical amp Flue horizontal in different zones pressure zones C12 Fig 34 16 1 16 2 16 3 Form 4420110 Sept 2010 RevA C52 Fresh air horizontal amp Flue vertical in different pressure zones Fresh air amp Flue horizontal in concetric ducts C32 Fresh air amp Flue vertical in concetric ducts Type A2 Outside ducted combustion air supply When installed in a dusty or polluted atmosphere the heater should be fitted with a ducted supply of clean fresh air A length of 100mm flexible ducting should be installed between the Control Box Air Inlet and any rigid ducting and be secured to the Air Inlet with hose clips Where outside combustion air is ducted directly to the burner s the low level natural ventilation openings shall be not less than 50 of the areas given in 6 4 2 1 above Type B22 When installing external flue single duct systems with ducted combustion air supply the distance between the flue terminal and fresh air intake shall be no less than 1 m for both vertical and horizontal systems TypeCi2 The
3. Burner Box 24 Assembly Torctite Coupling 2 each Fig 9 75 from end of EE to hanger Q N CRITICAL ASSEMBLY DETAIL 191 gt 127 end of U bend to reflector Spacing between the hanger brackets MUST be the dimensions shown 12mm to allow the fixed length side closure panels to be installed with room for movement during expansion and contraction of the heater during cycles rom hanger to burner suspension bracket 636 2099 2099 50 lt 768 gt gt WS 396 overlap go l Side View I I zi E La K D Lk 472 E 4198 pa Side Panel 711 from SN tube Side Panel 2057 2 each Models omanger A each ADU30 side Panel 160 1018 2 ES E Rade Tube T U Bend 2 each adiant Tube H ADU35 2 each 2 sach T TE u i N LA bt I i Bottom View I gt 305 711 f co a NG Torctite i Fan Coupling Assembly 4 each ie o 254 160 from end of end of U bend reflector to hanger to reflector End View Fig 10 Form 4420110 Sept 2010 Rev A 13 Side Panel 711 fro
4. lt m Sf Sf Sf Ss Sf ff a a af Ss as a am fF eck Saf ff Ss Ss st sch 19c 03333040 Pipe Nipple 1 2 NPT x 38mm 25kw control onl 20 4260367 _ _ Burner Clamp 21 4260370 Connector 76 2mm shown 21a 4260371 Connector 101 6mm 22 4260380 Bumer Bracket 23 4260541 Electrode 24 4262197 Ignition Control 25 4262280 Neon Light Red round 26 4262281 Neon Light Amber round 27 XXXXXXXX__ Gas Injector State Model amp Gas Type for Size 28 4260360x__ Bafile Plate State Model amp Gas Type for Size 29 4260362 Air Inlet Fabrication LABELS MANUAL Item No Part No Description Qty 30 4262036 Label Neon 1 31 4262035 Label Fan Power Supply 1 32 4260420 Label Warning GB IE 1 33 43344120GB Label Clearances to Combustibles 1 34 42848130GB Label Nameplate 1 35 4260440 Label Operating Instructions GB 1 36 4262000 Label Space Ray Logo 1 37 44201100 _ Installation Operation Manual 1 Form 4420110 Sept 2010 RevA 61 SH21VaH SVD GAYVYSNI Oj On Um 7 LE eel 22 e6 q96L 206 A UO SIOIDUOC MYGZ Form 44201100 Sept 2010 RevA 62 Fan Assembly Item No Part No Description Qty 1 4262256 Fan Unit Airflow 45BTFR 1 la 4262255 Fa
5. Tube Clamping Detail B U Bolt Clamps snug fit Fan Tube Burner Tube NN Z TE 7 DEE 7 ie 5 16 18 Nut Hanger Bracket Weld seam to the 5 16 18 Nut 1 each leg bottom of tubes 1 each leg p Fig 21g 7 Insert turbulators where required into the tube sections as described below A WARNING POISONOUS GAS AND SOOT HAZARD The heater must be assembled with the correct number of turbulator sections and tube length for the rated heat input The turbulators must be installed in the tube sections as shown below Failure to do so may result in death serious injury property damage or illness from Carbon Monoxide poisoning Form 4420110 Sept 2010 RevA 27 I Assemble the turbulators together by interlocking the slotted ends Il Slide these into the tubes at the U bend as shown for U Models HI Align the turbulator end flush with end of tube Note Refer to the table below for the number of turbulators required for each heater model Table 13 MODEL Turbulator Sections Burner Leg Fan Leg ADU 25 65mm x 572mm 2 2 ADU 30 90mm x 610mm 3 7 ADU 35 90mm x 610mm 3 6 ADU 40 90mm x 610mm 4 4 ADU 45 90mm x 610mm 4 1 U MODEL HEATERS Turbulators in Burner Leg at U Bend End DAL a zu Turbulators in Fan Leg at U Bend End so Turbulators TO insert in flat position a 65mm wide x 572mm long b 90mm wide x 610mm long
6. Bottom View Radiant Tube a 76 2mm b 101 6mm Fig 21h 8 Attach U Bend as described below ADU 25 U Bend 76 2mm Tubes I Assemble the U Bend to the tubes with the two 2 threaded holes facing downwards ensuring that the tubes engage fully ll Using two 2 5 16 BSW hexagon socket setscrews from fastening pack secure the U Bend to the radiant tubes ADU 30 35 40 45 U Bend 101 6mm Tubes I Assemble the U Bend to the tubes ensuring that the tubes engage fully ll Drill one 5 5mm hole through the U Bend and radiant tube in the lower surface of each leg at a distance midway along the swaged portion of the U Bend Ill Rivet the U Bend to the radiant tubes using the two 5 x 10 rivets provided from fastening pack Form 44201100 28 Sept 2010 RevA Note Welded seam of tube must be positioned on bottom side ADU 25 U Bend Attachment 76 2mm tubes 5 16 BSW Hexagon Socket Setscrews Bottom View EN 3 FL ADU 30 35 40 45 U Bend Attachment 101 6mm tubes Note Welded seam of tube must be positioned on bottom side Drill through 5 5mm Secure using 5 x 10 rivets Bottom View PF Ze NN Fig 21i 9 Position the lower reflector panels over the tube support hanger brackets Arrange the reflector panels to the dimensions shown in section 7 0 Note The reflectors MUST be positioned in accordance w
7. 2 Ifa flued installation disconnect the flue from the Fan 3 Loosen the nuts of the Torctite Coupling securing the Fan Connector to the Radiant Tube and draw the Fan Assembly off the Radiant Tube 4 Unscrew the three M6 x 12 setscrews and washers securing the Connector and Orifice Plate to the fan 5 Inspect the main impeller and secondary cooling impeller and remove any dust by brushing with a soft brush Check that the impeller rotates freely and that there is no excessive play in the bearings The bearings are pre lubricated and require no attention 6 When re assembling the Orifice Plate and Connector a new Gasket must be fitted between the Fan housing and Orifice Plate see Fig 46 Form 4420110 Sept 2010 RevA 59 19 0 CONVERSION INSTRUCTIONS CONVERSION FROM CAT 2H Natural Gas TO CAT 3P LPG a Remove the Injector from the Injector Fitting see Section 18 3 and replace it with the alternative Injector supplied with conversion kit Check that the size reference marked on the Injector agrees with that listed in the Specifications table Section 5 0 for the appliance model in question b Remove the pressure governor cap from the integral pressure governor of the Control Valve and screw the adjuster clockwise to increase the gas pressure check supply and manifold pressure in accordance with Section 11 0 Replace the pressure governor cap c Affix the gas adjustment label 3P G31 37mbar supplied with co
8. Form 4420110 Sept 2010 Rev A ADL30 35 Fig 7 11 6 5 ADL40 45 The appliances are supplied as follows Table 12 Carton containing the following 1 1 Fastenings Pack not shown 1 1 1 Burner Box Assembly 1 1 2b 44438510 Fan Assembly 4 less air plate 1 1 3 43318100 Hanger Bracket 7 7 4 4267924 Torctite Coupling 5 5 5 4250638 Radiant Tube 101 6 x 3048 4 4 6 4260174 Reflector Panel 3035 long 8 8 7 43319020 Reflector Panel 610 long 2 2 8 43320050 Reflector End Cap 2 2 9 44436130 Reflector Spacer Bracket 7 7 10 44152240 Turbulator 90mm x 610mm 8 4 11 44437960 Side Panel 2438mm 8 8 ila 44437360 Side Panel 914mm not shown 4 4 11b 44437061 Side Panel 160mm Not Shown 4 4 12 44441000 Side Panel Holder Bracket 14 14 ADL40 45_ Fig 8 Form 44201100 12 Sept 2010 RevA 7 0 DIMENSIONS U TUBE CONFIGURATIONS from hanger to burner suspension bracket Side Panel 457 691 243 gt gt 2099 gt lt 2099 gt 487 H 116 overlap In Side View E ILA oC P N 527 2 4198 m end of tube 2 each Models o hanger Side Panel 2057 ADU25 Side Panel 45 76 2 3 x 4572 4 each Hanger Bracket 2 each Radiant Tube SN 2 each 3 each 3 7 Fp Bottom View y 457 J MA
9. Jopayey puda ee r BEV 10 99lJ 3 gznav g N IAJ AO jqw ssy jeoidA ui Form 4420110 Sept 2010 Rev A 4aBuey o 1 uinq woi 92 109981 0 Jouung WO4 os SUOIONIJSUI UO e E SUI p ie p JO O 0L UONO9S OJ Jolox i i uleud uoisuadsns xog sawing d m pe yeyorsg 6602 JBP OH Isue spis wey a a BONE uoeo y xog sewing uoisu dsnS Buljdnog Alquassy m EN SOL ue p joued opis pres La ka m I N E SJ jeo1d Ay gt La ae on SINN X9H 9L S A AX uo z dusi yoq N I eee RAS 8v0 x qnl 7 9 LOL D u91ON Joes pu gt Pod Puy uoe uoeo z yeyoeigueBuey TSE x ONL 7 9 LOL fuoddns eqn ety N yoous suoyejnqun aer 2 pueg n Jeoeds 1049H hw fi yoee z BE SEOS 1o 99lJ93 See aw 1904S Zeg m senay oenav 10199149H pua Oaz 1019994 N IAJ AO Alquessvy eoldA Form 44201100 Sept 2010 RevA 16 gaBuey o 1 uinq woy PO 40 99y9J o JUNG woy SUONJNJISUI UOIJE BISUI POJIBISP JOJ O OL UONO9S o JSJSH E deano 10399431 uleyd 281 uoisuadsng I xog sewing deano 10990 L EI DW E OS ule me JoxPeIg lf Jap oy ug apis I u99 El xog sawing a Guljdnog jeued spis JB WOOL Alquiassy N E See ZE ue4 en F O yore SINN X H 91 9 o j yeyoelg Jabuey 3 duet yoq N dd Moddns eqny S 10 Se Teo puq yous 8v0 X qnl ut 9 SMOIOS JEJA 199US suoyejnquny
10. 21 0 Form 4420110 Sept 2010 Rev A Specifications ie ee avant EN Q u hyun Q ani ihe eee aus 5 Packing List Dimensions U Tube Configurations aaa naa aaa aaa aaa kaaa aaa aaa 13 Heater Assembly Overview U Tube Configurations 15 Dimensions Linear Tube Configurations we Heater Assembly Overview Linear Tube Configurations 19 Typical SUSPENSION Methods aa aaa aaa aaa aaa akan 22 Burner Box Support Details User Instruction Label I aS aaa aaa onak eede aaea iae aeie E aa ai danda ka ina U Tube Heater Assembly aaa vana m a a s aaa aaa usa Qua nana nana Linear Heater Assembly Tube Coupling Details Attaching Burner Box Assembly nt Attaching Fan Assembl 39 Gas Connections and Regulations 40 Instructions for Pressure Test Gauge Connection w AL Electrical Connections nana nana 43 Venting and Fresh Air for Combustion wn 44 Lighting and Shutdown Instructions 50 CommissioninNg aaa aaa 51 Cleaning and Annual Maintenance 51 Troubleshooting Guide 53 Replacing Rate teste nd bine iad hie A Ris ENEE ee eee 55 Removal of Electrodes aan naa nana a naa S aa na nan nana 55 Removing Main Burner x Removi
11. typical Refer to Section 10 1 for detailed installation instructions a N LO x o 3 i E Sai e o Ek 25 5 G oo G o es No SS s es SB g on nO e lt om o NOG o o O G E aco s E 5 s 5 Fre a a ra 8 v5 o5 2 v2 22 N NS oe VM Nk N M d M Vu 8 g Vu A a5 GA N S E Offs e IG 3 2 A PER M V AN nee oO s NN B a gt 56 V AN de A NN 4 o Ko 28 AN VH SS ab Vu AA EI 0 9 we a2 ae Oc O s j _ FE s mano Dw ag Qn as 88 eH om n D gt amp 5 239 me ech S so lt a S x Bi A per Si s 4 fse gt 5 s O E x 3 ge E oe o EE a a LEE E Se 9 i 5 m SO 5 GEO o me 9 Li KR reg vo ESA uze Fig 16 Form 4420110 Sept 2010 Rev A 19 Uafueu o JaUING woy Ken 1o 9 J 1 0 JOUING WOd oS suol onJ sul UOHe E SU PoJIEJSP JOJ 0L uol 93 S OJ JSJSH uieyo uoisuedsns xog Jeuung jeo1dA deano 104994491 Zeb Joxyoe1g 1 ploH ap opis deuaao 1O199 J 1 E A on 1 I po N uses v xog Jang Pi Sued epis RH eet me Se e L Sei pes z AN p uoS oN REENEN Genen e La a 0paienl pua a uoee g9 SINN XeH 91 9 Berg SE eg N yeyoeig Je6ueH BAWeIDWOSN ss Tt no S a 2 E ae yea pi ps Eeer svoe x eani H S10 e ec eg E yoe
12. A j 5 First Overlap Reflector Locking Clamp Lower Reflector 10 x 1 2 Sheet Metal Screw Fig 22f 9 Attach the reflector spacer brackets at each tube support hanger bracket using the 10 24 machine screws supplied in fastening kit See figure 22g below End View Reflector Spacer Bracket Es 10 24 mm Machine S Screw Hanger Bracket Fig 22g Form 4420110 Sept 2010 Rev A 35 10 Place the upper reflector panels over each of the reflector spacer brackets Repeat the same reflector positions and overlap dimensions as specified in table 16 see step 9 above To align reflectors precisely to the ends of the lower reflector hold the end cap in place against the lower reflector slide the upper reflector to rest against it See figure 22h below Align upper reflector panels flush to the end of the lower reflector panels dillejloo Fig 22h 11 Secure the upper reflector panels to the reflector spacer brackets as shown in figure 21i below Ill Screw through the reflector with the 10 self drilling screws into the reflector spacer bracket IV Repeat this at each hanger bracket specified in figure 22i Side View CAUTION Due to up to 40mm expansion The second to last hanger bracket on each and contraction during operation DO NOT heater is for reflector support only DO NOT CLAMP the reflect
13. Guljdnog S noio1 OyJOOL emol OCH yayoesq uoisu dsns 4auing 0 Jabuey woy 4099 OJ o kel ogni jueipey 4auing woy 989 groe X 14 9 LOL eqn Jueipeu ogni jueipey oS 8v0 X p 9 LOL Broe x Ub 9101 Aiquessy Buidnoo depieno Buggien xog ue m 96 demano ZL deano 121 KiC young a mares eh j SE snu ayOJOL J E y e selav Ss i oe1dav SISPO uoe 9 g ie P tz j P tz le P tz d F SL yeyoeig Jobuey Guijdnog Guljdnog 9 9 DAT Rote BS Deeg uoisu dsns 4auing 0 Jofueu woy qnl Jueipey 40 99 J94 o osa eqn juelpey Jauing uuolJ 989 Ger x 292 uge Z 92 gt ke ER Aiquessy Gujdnog deano Se veg ue4 omoop 89 depeno 821 depeno 844 Geier sowing N eg gt gt ke Wat SCHON H H 7 SlobO uveo 9 g lt ZIEL gt G t rhe 6872 de 68vZ gt lt SL Jon2p1g Jo6ueg Guljdnog OyJOOL 69 yayoesq uoisuedsns dauing 0 saBuey woy Fig 15 Form 44201100 Sept 2010 Rev A 18 8 1 HEATER ASSEMBLY OVERVIEW LINEAR TUBE CONFIGURATIONS The heater lengths for each input are shown in Section 5 0 Insure that all reflector screws and clips are in place to prevent the reflectors from separating during expansion and contraction of the heater The heater should be suspended to provide a slope of 0 25 degree up to the fan Assembly Suspension Chain 368 o reflector overlap Turbulators reflector overlap
14. M4 screw securing the valve bracket to the control valve and remove the grommet og Bon Slide out the complete assembly of gas valve ignition module and manifold After replacing the Control Valve check the gas pressures in accordance with Section 11 0 of this manual IMPORTANT TEST FOR GAS SOUNDNESS USING A SUITABLE LEAK DETECTION FLUID 18 7 REMOVING NEON INDICATOR Fig 44 1 Disconnect the electrical leads from the Neon Indicators by gently pulling the connectors using pliers 2 Remove the star washers 3 Press the neon indicator out through the mounting hole in the floor of the control box When replacing a Neon Indicator connect the electrical leads in accordance with the wiring diagram shown in Section 12 Form 44201100 58 Sept 2010 RevA 18 8 REMOVING AIR INLET PLATE Hex Nuts amp Washers Plate 3 each Pressure Front View Air Inlet Test Fitting access panel removed Assembly Air Switch Pressure Test Fitting Fig 45 1 After opening the control box door disconnect tubing from both brass pressure test fittings 2 Remove brass nut from pressure test fitting 3 Disassemble components from the control box 18 9 REMOVING THE FAN Fan Unit I Gasket Air Restrictor Plate Connector 0 101 6mm Coupling ka Tube Connector g 76 2mm Fig 46 1 Disconnect the electrical wires from the fan see Section 12 0 for connection details
15. Reflector End Cap Notched 1 1 42896100 Reflector End Cap Plain 1 1 44436280 Reflector Spacer Bracket 3 3 44152240 Turbulator 990mm x 610mm 10 4 44437810 Side Panel 2057mm 4 4 44437280 Side Panel 711mm Not Shown 2 2 44437061 Side Panel 160mm Not Shown 2 2 6 6 ADU30 35 Fig 4 Form 44201100 8 Sept 2010 RevA 6 2 ADU40 45 The appliances are supplied as follows Table 9 REFNO PARTNO DESCRPTON ww ADU45 mc Oconee Fastenings Pack not shown Burner Box Assembly 44438510 Fan Assembly 4 less air plate 4260374 U Bend 42898100 Hanger Bracket 4267924 Torctite Coupling 4250638 Radiant Tube 101 6 x 3048 42894100 Reflector Panel 3035 long 4260376 Reflector Panel 2540 long 4260377 Reflector Panel 1511 long 42895100 Reflector End Cap Notched 42896100 Reflector End Cap Plain 44436280 Reflector Spacer Bracket 44152240 Turbulator 990mm x 610mm 44437960 Side Panel 2438mm 44437280 Side Panel 711mm Not Shown 44437061 Side Panel 160mm Not Shown 44441000 Side Panel Holder Bracket x Y 8G 8 ADU40 45 Fig 5 1 2 3 4 5 6 8 9 N A P ol Al P P N N N E p p P P P H N lo ay P P N N N El p p P P P P 00 00 Form 4420110 Sept 2010 Rev A 9 6 3 ADL25 The appliances are supplied as follows Table 10 REF NO PART NO MODEL Carton containing th
16. RevA 6 0 PACKING LIST 6 1 ADU25 The appliances are supplied as follows Table 7 PART NO DESCRIPTION AD2 Carton containing the following 1 Fastenings Pack not shown 1 1 Burner Box Assembly 1 2 44438010 Fan Assembly 3 less air plate 1 3 4260021 U Bend 1 4 42773100 Hanger Bracket 3 5 4267923 Torctite Coupling 2 6 4260020 Radiant Tube 76 2 x 4572 2 7 4260375 Reflector Panel 2438 long 4 8 42762050 Reflector End Cap Notched 1 9 42761050 Reflector End Cap Plain 1 10 44436180 Reflector Spacer Bracket 3 11 44152248 Turbulator 65mm x 572mm 4 12 44437810 Side Panel 2057mm 4 12a 44437180 Side Panel 457mm not shown 2 12b 44437011 Side Panel 45mm not shown 2 13 44441000 Side Panel Holder Bracket 6 ADU25 Fig 3 Form 4420110 Sept 2010 Rev A 7 6 2 ADU30 35 The appliances are supplied as follows Table 8 REFNO PARTNO DESCRPTON auo ADUSE LL Garon eonainngtnefolown8 E a Fastenings Pack not shown 1 1 1 Burner Box Assembly 1 1 2 44438020 Fan Assembly 4 with air plate 1 1 3 4260374 U Bend 1 1 4 42898100 Hanger Bracket 3 3 5 4267924 Torctite Coupling 4 4 6 4250638 Radiant Tube 101 6 x 3048 2 2 7 4250637 Radiant Tube 101 6 x 1524 2 2 8 42894100 Reflector Panel 3035 long 2 2 9 4260376 Reflector Panel 2540 long 2 2 42895100
17. ae u9e9 p N jeyoeig Jeoeds Jopeyoy iak z SMOJOS lt N G 0 Jee ia aus 7 uleld 1099494 Puy Spnav 8 Ornav l N IAI AO Ajquiessy edidA yoke z Orsz 40 99lJ934 S z Let open Form 4420110 Sept 2010 RevA 17 8 0 DIMENSIONS LINEAR TUBE CONFIGURATIONS Aiquossy ue4 919401 K s9 949 Duunp 1 1e u y JO UONJBJIJUOJ pue UOIsuedxo GULINp JUSLUSAOW JOJ WOOL UA POJJEISUI q o Sjeued inso o spis y 5u poxij sul MOIE O UIUIZ UMOYS SUOISUBLUIP u 94 Lem s eyoeJg JeGuey au U SMJST Buloeds MWLAd ATEWASSV YILI NOILAVO W 109991 o yoee A jeyoesg 1o6ueg uey M JA pug Js wng MAIA pug WEEN aqn jueipey aqn jueipey eqn JUeIPeY Son jueipey Pee 96 oboe x cb 9101 svoe X Li 9 LOL groe x 9 9401 groe x Li 9101 aa Guljdnog deueno Guljdnog gg deano zz depeno ZZ depeno ZZ aio isune j K gt gt Z E d Y leet svay tf Baler SJ PON g t6 687z 687 6877 lt G t gt z t Guljdnog Guljdnog
18. below Reflector End Cap typical opposite end of heater a Nez Sheet Metal Screws 4 places Fig 22k 15 Make all final gas and electric connections as outlined later in the instructions 10 2 TUBE COUPLING DETAILS Join the tube sections together and secure with tube couplings as described below Note The heater tube section should be provided a slope of 0 25 degree up to the fan The following coupling tightening instructions MUST be AWARNING followed properly to ensure the integrity of the tube connections Two 10 self drilling screws MUST be installed at every coupling as shown in the instructions below Failure to do so may result in serious injury or property damage a Place the compression coupling over the end of the tube b Use the small hole at the centerline of the coupling to check that the coupling is inserted correctly c Partially tighten the bolt nearest the end of the tube approximately half closed Form 4420110 Sept 2010 RevA 37 Tube Center end of Tube with hole Tube Coupling Partially tighten this bolt 3 Fig 23 d Slide the next tube into the coupling e Make sure both tube ends are butted together f Finish tightening both bolts to 54 80 N m torque to ensure a complete seal g Use the two self drilling screws through the pre punched holes to secure the tubes in the coupling A Center both tubes with hole e Coupling 10 Self Dr
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20. each leg bottom of tubes 1 each leg Fig 21 Form 44201100 24 Sept 2010 RevA Tube Clamping Detail A ADU 30 35 40 45 First Tube u Bol Clamp U Balt Clamp Section Assembly with clearance snug TI Fan Tube l H Burner Tube Mf wr Om Burner Tube 5 16 18 Nuts Hanger Bracket Weld seam to the 5 16 18 Nut 2 each leg bottom of tubes 1 each leg Fan Tube ADU 30 35 2099mm ADU 40 45 2489mm Fig 24a L Place tubes over the hanger brackets with the welded seam facing down toward the ground Failure to assemble the tube with the seam facing down will void the manufacturer s warranty Il Secure the tubes to each support hanger bracket using U bolt clamps and 5 16 18 nuts provided See Details A or B of Fig 21 and 21a for required U bolt tightening sequence 4 Raise the tube section up to the suspension chain or other methods using S hooks to attach the tube support brackets close S hooks after they are attached to the hanger brackets Hang each tube section individually DO NOT attach all of the heater tube sections together on the ground and attempt to hang the entire system 5 For models ADU 30 35 suspend the hanger bracket for the second section of tube raise the tubes into position and join the tube sections together using Torctite couplings as described in Section 10 2 Tube Coupling Details Fasten the tubes to the hanger bracket See figure
21. in excess of 6OkW total rated heat input Where the air supply openings can be closed it shall only be possible to operate the radiant heaters when they are open MECHANICAL VENTILATION Ventilation shall be provided in all cases at or below the level of the heaters Minimum proven air flow 2 35m3 h kW of total rated heat input It shall only be possible to operate the radiant heaters whilst the ventilation airflow is proven C FLUE AND COMBUSTION AIR CONFIGURATIONS The heaters can be installed with different flue and combustion air configurations please review the diagrams on the following page for the overview of the permitted installations The permissible maximum lengths associated with these options are listed in the table below Table 18 Flue Max Max Flue Max flue length Max length Reduce length Reduce length Type Combustion Length Concentric combined for 90 bends for 90 bends Air 100mm 100mm 0 150 100mm combustion air 100mm concentric g and flue A2 15m N A N A 15m 1 7m N A B22 13m 15m N A 28m 1 7m N A C124 8m im 8m m im 8m 9m 1 7m 2 5m terminal C321 8m m 8m im im 8m 9m 1 7m 2 5m terminal Cs2 13m 15m N A 28m 1 7m N A 46 Form 44201100 Sept 2010 RevA A2 B22 B22 Notet first length is parallel section second length is concentric section Fresh air horizontal A2 Fresh air vertical
22. n IGNITION MODULE Y YELLOW CONNECTION Fig 33 13 0 VENTING AND FRESH AIR FOR COMBUSTION A WARNING POISONOUS GAS AND SOOT HAZARD Heaters installed unvented must be installed in an area with at least 10m hr per kW heat input of outside air ventilation In buildings with airborne contamination such as poultry houses the heater must be installed with fresh air for combustion Failure to do so may result in death serious injury property damage or illness from Carbon Monoxide poisoning These appliances may be installed with an exhaust flue fitted or without an exhaust flue fitted A FLUELESS UNFLUED The installation room should have a volume of at least 10m3 kw of installed nominal heat input of the radiant heater The ventilation requirements and calculation methods for unflued appliances are set out in the European Standards EN 13410 2001 and must be applied The following is guidance to the standard Form 44201100 44 Sept 2010 RevA Ventilation may be achieved by any of the three following different means a thermal evacuation of the products of combustion air mixture b mechanical evacuation of the products of combustion air mixture c natural air change VENTILATION BY THERMAL EVACUATION a Ventilation by thermal evacuation is sufficient if 10m h of exhaust air per kW of operating heat input are ventilated out of the installation room b The air products of combustion mixture must be e
23. 21b c and d below for installation sequence ADU30 35 Second Tube Section Assembly End Hanger Bracket Torctite Couplings N First tube section 2099mm Fig 21b Form 4420110 Sept 2010 Rev A 25 Install each tube individually and tighten torctite couplings First tube section Fig 21c First tube section Tube Clamping Detail B U Bolt Clamps snug fit Me Burner Tube SI 7 kru 7 a 5 16 18 Nut Hanger Bracket Weld seam to the 5 16 18 Nut 1 each leg bottom of tubes 1 each leg Fig 21d 6 For models ADU 40 45 suspend the hanger bracket for the second section of tube raise the tubes into position and join the tube sections together using Torctite couplings as described in Section 10 2 Tube Coupling Details Fasten the tubes onto the hanger bracket See figure 21e f and g below for installation sequence ADU40 45 Second Tube Section Assembly End Hanger Bracket bt Torctite Couplings First tube section 3254mm Form 44201100 26 Sept 2010 Rev A Install each tube individually and tighten torctite couplings First tube section Tube Clamping Detail A U Bolt Clamp U Bolt Clamp with clearance snug fit Fan Tube Burner Tube GE 6 35mm H clearance A P i 7 A 5 16 18 Nuts Hanger Bracket Weld seam to the 5 16 18 Nut 2 each leg bottom of tubes 1 each leg First tube section
24. ADL30 45 760mm 610mm 2285mm 610mm 760mm A WARNING Certain materials or objects when stored under the heater will be subjected to radiant heat and could be seriously damaged Observe the Minimum Clearances to Combustibles listed in the manual and on the heater at all times NOTE 1 The clearances specified above must be maintained to combustibles and other materials that may be damaged by temperatures 32 C above ambient temperature Clearances to combustibles are posted on the control box In areas used for storage of combustible materials where they may be stacked below the heater It is recommended that the installer must post signs that will specify the maximum permissible stacking height to maintain the required clearances from the heater to combustibles Space Ray recommends posting these signs adjacent to the heater thermostat or other suitable location that will provide enhanced visibility 2 The stated clearance to combustibles represents a surface temperature of 32 C above room temperature Building materials 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 Form 44201100 4 Sept 2010 RevA 5 0 SPECIFICATIONS Table 2 A2 B22 C12 C32 C52 Adjusted for 2H G20 20mbar 3P G31 37mbar
25. E N a Ki r uonoeuuo9 eda u UOJIMS JIE aoe dex j u 6eyoolq snowy j u uolo uuoo ned y j u uolo uuoo ned y j u uolo uuoo dedo d Iy a ova ova SN ova ova ON gt a DA La a N r uono uuo3sN s UONOBUUDD ra gt aed asoo Aue aal soo Aue J0 e91pu uo u uo uuo2 JOJEJIPUI onp JIE uo ajddiu s pue SI X90 q Jeu pue aal S Us Je pue Jaquue y uo Ajaunoes ON uoeu eoug y s oq N GunueA zsneyx y ul ASSA uols ue usemjeq ON soyesipul uoau seque ON Jojeoipui uoau saqwe SA sjeuiwa as m KON xoq onuoo Oy Joyeolpul YOUMS ue JE WOO Jo J9Np sje YSey Y ul pajeysul Au doid u m q uonlo uuoo u m q uonloa uuoo peaj and pue aim ul UO WOOD JOJE IPUI uoeu Jaquie ovejdew J _ pue ON ou 1 dunr j aBey901q Aue 1194 sl u asoy 11e ou S SUM ang eu 49940 SUM JIOIA au 9949 J __ peal ap au ay uoeu Jaque y seo LN a N a lnpouu q uoniuBi ooejdew q uoljo uuoo jede ON ON e N N N e gt Auesseoau yyes pue uonq9euuo9 Ida lnpoui uous su UEJ o 1 EUIWI9 pue S A JO X9X0 q Ieuluu su Lea lnpouu uoniuBi y G Iguluu19 u wl q JO G Bull u wq q 0 p 5 38uuoo lu doid Sain u youq Jeden Aununuoo y 499 NOEZ 3194 S 90 q jeur u S uoll9 uuoo ujeda ki sl Inu UY uo C u d 3 Iq I u d u aj I Sai ON oja e N N La gt amp X0q Ou u yoiq y u X90 q Ieuluu uey ON aim uy s m SAA uljouono suej ON
26. H 2 gl J IT gt First Hanger bracket to First Overlap O1 Second Overlap O2 Third Overlap O3 Fourth Overlap O4 the end of the reflector Dimension A Fig 22e 8 With the lower reflector panels in place secure the reflectors to the hanger brackets on both sides of the reflector as shown in figure 21f IV From the underside of the hanger bracket drive in the sheet metal screw until the tip is just through the reflector panel V Position the Reflector Locking Clamp over the screw and continue to drive the screw until the reflector is secured in place VI Repeat this at each hanger bracket specified in figure 22f Note the reflector is NOT clamped at the second and second to last hanger bracket on every model A CAUTION CRITICAL ASSEMBLY DETAIL a gt j The reflector MUST NOT be clamped at the second hanger bracket The reflector must be able to move freely through the hanger bracket when the heater operates Failure to allow the reflector to move will result in severely distorted reflector panels Side View CAUTION Due to up to 40mm expansion The second to last hanger bracket on each and contraction during operation DO NOT heater is for reflector support only DO NOT CLAMP the reflector at this bracket CLAMP the reflector at this bracket First Reflector R1 Second Reflector R2 Third Reflector R3 Fourth Reflector R4 Fifth Reflector R5 SR i e 7 I a
27. LLOW a i BLUE Continue To gt Additional L BROWN Heaters Thermostat zeree Thermostat zenic o E 4 oS Ka Ea 1 2 2 7 7 Heater 1 Heater 2 Fig 31 Multiple Heaters per Thermostat connection diagram E _GREEN YELLOW u BLUE Continue To gt Additional L BROWN oko e Heaters Service Service Thermostat Switch Switch S 1 2 2 7 7 Heater 1 Heater 2 Fig 32 Notes The method of connection to the electrical supply must facilitate complete isolation and should preferably be via a fused double pole isolator having a constant separation of at least 3mm in all poles and supplying the appliance ONLY Alternatively connection may be made via a fused 3 pin plug and un switched shuttered socket both complying with the requirements of National or Local Regulations Neither thermostat nor switch are supplied as standard equipment NOTE In the event of an electrical fault after installation of the appliance preliminary system checks are required to be carried out i e earth continuity polarity and resistance to earth Form 4420110 Sept 2010 RevA 43 c Internal Wiring Diagram POWER IN TO FAN AMBER NEON RED NEON AIR SWITCH WIRING COLOUR CODES BL BLUE BR BROWN GR GREY Coon GR G Y GREEN amp YELLOW mmm Lal I 123456789101112 35 VLEI gee J ELECTRODE
28. SPACE RAY INSTALLATION AND OPERATION INSTRUCTIONS OVERHEAD RADIANT TUBE HEATERS Models ADU25 ADU30 ADU35 ADU40 ADU45 ADL25 ADL 20 ADL35 ADL40 ADL45 Single Stage Pull Through System Negative Pressure C lt MANAGEMENT 0 0 86 Energy Association OWNER INSTALLER For your safety this manual must be carefully and thoroughly read and understood before installing operating or servicing this heater This heater is intended for use with either Natural Gas or Propane Gas It must be installed by a qualified service person or a licensed contractor in accordance with National and local codes A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operation and maintenance instructions thoroughly before installing or servicing this equipment For assistance or additional information consult a qualified installer service agency or the gas supplier INSPECT all combustion air openings into the building and if necessary clear if they become blocked by dust FOR YOUR SAFETY If the heater is installed without a flue exhaust fans MUST be operating on an appropriate cycle when heaters are operating to avoid a high concentration of carbon monoxide When used without fresh air this heater may give off carbon monoxide an odorless and poisonous gas CARBON MONOXIDE POISONING MAY LEAD TO DEATH Early signs of carbon monoxide poisoning
29. Safety Installations and Use Regulations 1998 for gas fired products Installation practices must take into account 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 2001 BS 6896 2005 Industrial amp 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 Clearances to combustibles as outlined in the manual should always be observed In areas used for storage of combustible materials where they may be stacked below the heater the installer must post signs that will specify the maximum permissible stacking height to maintain the required clearances from the heater to combustibles Every heater shall be located with respect to building construction and other equipment so as to permit access to the control housing Each installer shall use skillful and reliable installation practices when locating the heaters and must give consideration to service accessibility This heater is for INDOOR INSTALLATION ONLY and is used in VENTED or UNVENTED mode The term Unvented actually means Indirect Vented While the products of combustion are expelled into the building national codes require ventilation in the building to dilute these products of combustion This ventilation must be provided by gravity or mech
30. Section 9 Typical Suspension Methods Space the suspension points according to the hanger bracket spacing dimensions see section 8 0 for each heater Use spanning steel work if necessary to position suspension points Note Suspension points are fixed along the length of heater to accommodate the side panels 3 Space the hanger brackets according to the dimensions shown in the figures below for the first tube section Note The distances are measured from center of the holes of each support hanger bracket See figure 22 below N _ U Bolt Clamp U Ye snug fit NJI Ba T 7 WCS Hanger Bracket Weld seam to the 5 16 18 Nut bottom of tubes 1 each leg Typical attachment method for every hanger bracket Fig 22 Form 44201100 32 Sept 2010 RevA IL Place tubes over the hanger brackets with the welded seam facing down toward the ground Failure to assemble the tube with the seam facing down will void the manufacturer s warranty IV Secure the tubes to each support hanger bracket using U bolt clamps and 5 16 18 nuts provided See Fig 22 for required U bolt tightening sequence 4 Raise the tube section up to the suspension chain or other methods using S hooks to attach the tube support brackets close S hooks after they are attached to the hanger brackets Hang each tube section individually DO NOT attach all of the heater tube sections together on the ground and attempt to hang the entire s
31. Sengres Sma ee Burner Baffle Plate PN 4260360C Fan Air Restrictor Plate None Electrical Supply 230V 50Hz 125W Dimensions ADU25 5385mx0465m ADIZS 40055mx034m ADU25 47kg ADL25 46kg Table 3 MODEL ADU30 ADL30 N ADU30 ADL30 L EE Appliance Type use A2 B22 C12 C32 C52 Appliance Category ll H3P Adjusted for 2H G20 20mbar 3P G31 37mbar Setting Pressure oompa mbar Injector Burner Baffle Plate PN 4260360D Fan Air Restrictor Plate PN 42741170 Electrical Supply 230V 50Hz 125W ADU30 5 51m x 0 715m ADL30 9 955m x 0 34m ADU30 66kg ADL30 62kg groom Table 4 MODEL ADU35 ADL35 N ADU35 ADL35 L SE Appliance Type use A2 B22 C12 C32 C52 Appliance Category Ilau3P Adjusted for 2H G20 20mbar 3P G31 37mbar Setting Pressure ia Ember mbar Injector Burner Baffle Plate PN 426036L Fan Air Restrictor Plate None Dimensions ADUS Simom ADL35 9S55mx032m Form 4420110 Sept 2010 Rev A 5 Table 5 MODEL ADU40 ADL40 N ADU40 ADL40 L Heat Input 42 2kW Hs 38 0kW Hi SP G3r Tbe mese o mr o Injector Burner Baffle Plate PN 4260360T Fan Air Restrictor Plate None EELER Table 6 MODEL ADU45 ADL45 N ADU45 ADL45 L EE A2 B22 C12 C32 C52 CSL STi egen E YY Injector Burner Baffle Plate PN 4260360U Fan Air Restrictor Plate None Dimensions mme armes ADLAS mom Form 44201100 6 Sept 2010
32. TY SUPPLY RED amp AMBER NEON INDICATOR ON BURNER SHOULD IGNITE WITHIN 15 SECONDS AMBER NEON INDICATOR ON IF IGNITION IS NOT ACHIEVED DURING 12 SECOND IGNITION PERIOD LOCOUT OCCURS THIS IS INDICATED BY THE AMBER NEON OFF INTERUPT ELECTRICITY SUPPLY TO APPLIANCE FOR 10 SECONDS TO RESET IGNITION CONTROL IF A FIRST RESET IS NOT SUCCESSFUL WAIT AT LEAST 15 SECONDS BEFORE REPEATING PROCEDURE AFTER RESET AN EXTENDED WAITING TIME WILL OCCUR IF FLAME IS LOST DURING NORMAL RUNNING THE AUTOMATIC IGNITION CONTROL WILL REPEAT START PROCEDURE AS AT 4 ABOVE IF THE APPLIANCE FAILS TO IGNITE AFTER SECOND START SEQUENCE SWITCH OFF ELECTRICITY SUPPLY TO APPLIANCE AND CALL SERVICE ENGINEER TO SHUT DOWN APPLIANCE TURN OFF GAS AND ELECTRICITY SUPPLIES AFFIX THIS LABEL ADJACENT TO LOW LEVEL USER CONTROL 4260440 Fig 20a Form 4420110 Sept 2010 RevA 23 10 0 U TUBE HEATER ASSEMBLY CAUTION CUT HAZARD Sheet metal parts particularly reflectors and vent have sharp edges Always use gloves when handling Failure to do so may result in death serious injury or property damage See heater dimensions and assembly overview Sections 7 0 and 7 1 for each U model configuration It is recommended to read the all the instructions carefully before proceeding with the installation During field assembly of the heater body sections the recommended procedure is as follows 1 Determine the actual layo
33. The installer is responsible for the following e The heater and venting as well as electrical and gas supplies must be installed in accordance with these installation instructions and any applicable codes and regulations e Every heater shall be located with respect to building construction and other equipment so as to permit access to the heater e Each installer must follow the clearances to combustible materials for the heaters e Install the heater so that the supports and hangers are correctly spaced in accordance with these instructions The heater must be supported by materials having a working load limit of at least 52kg e Supply the owner with a copy of these Installation and Operation Instructions e Never use the heater as a support for a ladder or other access equipment Do not hang anything from the heater e Supply all installation materials necessary that are not included with the heater e Check the nameplate to make sure that the burner is correct for the gas type in the building 3 0 GENERAL INFORMATION This heater is a self contained infrared radiant tube heater designed for use where flammable gases or vapors are not generally present Installation of this heater must be in accordance with all applicable codes shown in the instructions and or the local codes and authorities having jurisdiction In the UK all equipment must be installed and maintained in accordance with the relevant provisions of the Gas
34. anical means Ventilation requirements are addressed further in these instructions Although these heaters may be used in many applications other than space heating e g process heating Space Ray will not recognize the warranty for any use other than space heating Form 44201100 2 Sept 2010 RevA This heater is not an explosion proof heater Where the possibility of exposure to volatile and low flash point materials exists it could result in property damage or death This heater must not be installed in a spray booth where the heater can operate during the spraying process Consult your local fire marshal or insurance company Linear Configuration Series Only Since linear configuration tube heaters are always hotter at the control end than at the flue terminal end always observe the minimum recommended mounting heights Fig 1 Form 4420110 Sept 2010 RevA 3 4 0 MINIMUM CLEARANCES TO COMBUSTIBLES A WARNING FIRE AND EXPLOSION HAZARD Combustible material must be located outside the clearance dimensions listed Failure to do so may result in death serious injury or property damage Minimum clearances to combustibles shall be measured from the outer surfaces as shown in the following diagram END lt gt END ABOVE CEILING ABOVE CEILING 4 Fig 2 Table 1 MINIMUM CLEARANCES TO COMBUSTIBLES Side Above Below End ADU25 ADL25 510mm 450mm 1220mm 510mm 610mm ADU30 45
35. as Form 44201100 60 Sept 2010 RevA 21 0 REPLACEMENT PARTS GUIDE The following is a list of replacement parts which may be required during the life of the appliance CONTROL COMPONENTS Item No Part No Description Qty 1 02330010 Vinyl Cap 1 2 02331010 Plug Liquid Tight Hole 1 3 4262151 Inlet Male Pin PX0575 1 3a 4262153 Outlet Female PX0695 1 4 30700040 Grommel Pipe Sealing 1 5 6 44190250 Housing welded 7 44193260 Access Panel with hinge 8 44202000 Turnbuckle Holder Bracket 8a 30545040 Turnbuckle Not shown 9 03988070 Tubing Silicone 178mm Lg Not shown 10 2113 Pressure Test Point 11 4260363 Test Nipple 12 4262322 Brass Locknut 13 4250600 Burner Fabrication 13a 42700000 Burner 25kw controls only 14 4250625 Air Switch Assembly 15 4250696 Gas Valve Assembly complete 15a 4262586 Gas Valve VK4105C 15b 4262552 ___ Flange 1 2 BSPT Straight 15c 4260502 Pipe Nipple 1 2 BSPT x 110mm 15d 4260382 Valve Bracket 15e 4262551 Flange 1 2 BSPT Elbow 16 42506950 Wiring Harness less H T cable Not shown 17 42510929 HIT Cable 178mm Lg Not shown 18 4260132 Gasket 19 4260364 __ Injector Fitting 1 2 BSPT x 7 8 UNF 19a 42701000 _ Injector Fitting 1 2 NPT x 5 8 UNF 25kw controls only 19b 03540090 _ Coupling 1 2 NPT 25kw controls only
36. at 3 5mm and that the tips of the flame sensor and spark electrode are free from deposits Clean off any deposits Check that the electrode ceramic is free from cracks See Section 18 1 e Suspension system Check that the suspension system is holding the heater level Make sure that the heater is hanging securely look for any evidence where the heater may have been hit accidentally and tighten any loose hanging points Check that S hooks are closed Check that there is no evidence of wear on the chain at the connection to the heater and at the ceiling e Main Burner and Orifice Check the Main burner and orifice remove any dirt or debris including spider webs See Sections 18 2 and 18 3 e Electrical Wiring Check that all the electrical connections are sound and that the wiring is undamaged Replace damaged wires as necessary e Air Inlet Baffle Plate Check that the air inlet holes in the Baffle Plate which is clamped between the Control Box side panel and the Air Inlet flange are clear from obstructions Check also that the wire mesh panel of the Air Inlet is clean Clean as necessary using a soft brush In the case of an appliance having a ducted air supply it will be necessary to disconnect the flexible ducting from the Air Inlet by first releasing the hose clip If it is necessary to remove the Air Inlet to adequately clean the Baffle Plate it will be necessary to replace the gasket seal see Section 18 8 e Door Seal Check the condi
37. ay ye suono uuoo K ON peaj Joou yoayo pue uo N pue q u w q 241M BUOJM JO Jojow o d JOMOd y 09uuoosi d Oo Vi Uy yo Si S AOEZ 2194 sI u soo Aue 1 u av L uo UEL y S Sat a gt A a gt e N yney edau 6unoous lqnon pue e soway Je u uejsay uonoeuuoo eday uono uuoo edel VER Jomod RE ON h ON ova ON 3 a N N gt a N J0 e9 pu uo u XOq 0 quo9 eu xoq pes ay uo Ajasnoes amp X0q 0 uo9 eut UI X90 q eUIWJe su IO uoo y ul UO SU SOA loyeoipul uoau SA sjeuluue aw DN ur yooq jeu oy SA jo uonoas j amod AON uoljeoipui uoau pal JOJEYIPUI p 1 y uo sjeu peaj and pue aim ye uollo uuo2 Duo UO N pue q u w q y s oq 1e souus u uo u pal au Soeld x J SSODE A0gZ 8194 S pea umoig y aly J 40 9800 Aue aiaut si u AOEZ 2494 sl J N pue Jamod uo un Form 4420110 Sept 2010 Rev A a 3 gt 3 2 E N 5 5unoous lqnon 5unoous Iqnon Ups pejsay oinssaid aunssaid ou WWUG 0 se pjopuew 1sn i B5eyoolq Jee A BA SEG vejd a se6 Ajddns en Addns se6 oun abun de6 ueds au en d Ploy 1 Pwj 49014 Hl I I a I D Pv
38. cient natural air change in the installation room Furthermore no provision for thermal or mechanical ventilation is required in the following particular cases Buildings with natural air change greater than 1 5 volumes per hour Buildings with a density of operating heat input not greater than 5W m AIR SUPPLY Air supply openings are required to admit air and shall be located below the radiant heaters The total area of the unobstructed cross sections of all the air supply openings shall not be smaller than the total area of the unobstructed cross sections of all the exhaust openings Slits and gaps of fixed cross section can also be used as air supply openings Where the air supply openings can be closed it shall only be possible to operate the radiant heaters when they are open Form 4420110 Sept 2010 RevA 45 B FLUED If the appliance is to be flued externally then flue pipe of diameter stated in Table 12 and complying with National and Local Regulations should be used IMPORTANT When flued horizontally the flue pipe must be arranged to provide a continuous rise from the appliance of 25mm per 1m length The ventilation requirements for flued appliances are set out in BS 6896 2005 and must be applied The following is guidance to the standard NATURAL VENTILATION Low level ventilation shall be provided in all cases below the level of the heater s Up to and including 60kW 4 5cm2 kW Over 60kW 270cm 2 25cm2 kW
39. e 9 gt jeyoeig Jaoeds 10 aay siole nqini A quwessy ueq ees Koo r seqay 9 0 1dv es N IAJ AO Alquessvy eoldA Fig 17 Form 44201100 Sept 2010 Rev A 20 Fan Assembly See Detail B 55 lt reflector overlap a Turbulators 127 a reflector overlap typical Reflector 610 2489 Refer to Section 10 1 for detailed installation instructions from burner to reflector s i EZ E os El z 8 N S38 SS zoom s y MAMA NE s ANE NAN gt st N a g NN A N gt N NAN s 83 O lt Be NN N g g S 2 WV NAR EN 1 lt a A A VW A lt WW NA F o gt N AN WW Sheet Metal Screws N a j Q ps Reflector Spacer a Se a Lac Bracket Teach N a 2 End Reflector Burner Box Notched 2 each Fig 18 Form 4420110 Sept 2010 Rev A 21 from burner to hanger 9 0 TYPICAL SUSPENSION METHODS Not withstanding their limited scope the appliance should be installed in accordance with the relevant provisions of any National Gas Safety Installation and Use Regulations Due account should also be taken of any obligations arising from any National Heath and Safety at Work Regulations National and Local Building Regulations and National Electrical Wiring Regulations The appliance must be installed and where necessary converted for use on other ga
40. e following Fastenings Pack not shown 1 1 Burner Box Assembly 1 2 44438010 Fan Assembly 3 less air plate 1 3 43318100 Hanger Brackets 6 4 4267923 Torctite Coupling 3 5 4260020 Radiant Tube 76 2 x 4572 2 6 4260176 Reflector Panel 3035 long 6 7 43319020 Reflector Panel 610 long 2 8 43320050 Reflector End Cap 2 9 44436130 Reflector Spacer Bracket 6 10 44152248 Turbulator 65mm x 572mm 6 11 44437960 Side Panel 2438mm 6 ila 44437250 Side Panel 635mm not shown 4 11b 44437011 Side Panel 45mm not shown 4 12 44441000 Side Panel Holder Bracket 12 ADL25 10 Fig 6 Form 44201100 Sept 2010 Rev A GA ADL30 35 The appliances are supplied as follows Table 11 Carton containing the following Fastenings Pack not shown 1 1 Burner Box Assembly 1 1 44438020 Fan Assembly 4 with air plate 1 44438030 Fan Assembly 4 less air plate 1 43318100 Hanger Bracket 6 6 4267924 Torctite Coupling 4 4 4250638 Radiant Tube 101 6 x 3048 3 3 4260174 Reflector Panel 3035 long 6 6 43319020 Reflector Panel 610 long 2 2 43320050 Reflector End Cap 2 2 44436130 Reflector Spacer Bracket 6 6 44152240 Turbulator 90mm x 610mm 9 4 44437960 Side Panel 2438mm 6 6 44437250 Side Panel 635mm not shown 4 4 44437061 Side Panel 160mm Not Shown 4 4 44441000 Side Panel Holder Bracket 12 12
41. eriods of time switch of the electricity supply to the appliance and turn off the gas supply at the gas isolation valve Form 44201100 50 Sept 2010 Rev A NOTE The lighting and shutdown instructions are also shown on a permanent label attached adjacent to the controls for the heater see section 9 2 15 0 COMMISSIONING The chart below shows the sequence of operation for the normal operating cycle Thermostat Blower Red neon indicator Air switch Amber neon indicator Ignition Gas valve Flame sensing Call for heat Thermostat on 20 secs pre purge 10 secs trial for ignition Normal operation flame sensing Thermostat off Heater OFF O Function ON Function OFF Fig 37 If the flame is not sensed during sequence T3 then the heater will go to lockout It is essential that all new pipework installations are purged and tested for soundness with a suitable leak detection fluid prior to attempting to ignite any appliance This work should be carried out in accordance with National or Local regulations NOTE DO NOT TEST FOR SOUNDNESS BY USE OF NAKED FLAMES 16 0 CLEANING AND ANNUAL MAINTENANCE AWARNING ELECTRIC SHOCK amp EXPLOSION HAZARD Disconnect electrical power and gas supply before servicing Failure to do so may result in death or serious injury This heater must be cleaned and serviced annually by a qualified contractor before the start of each heating sea
42. ers g Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent structure with adequate load capacity h The appliance may be mounted horizontally or at a recommended angle of 30 maximum to the horizontal i Hanging points are fixed along the length of heater to accommodate trim pieces Secondary steel work may be required to span between supporting beams j The appliance should be located with respect to building construction and other equipment to permit access to the appliance for servicing etc Space Ray recommends that the body sections be suspended using chains with turnbuckles This will allow slight adjustments after assembly and heater expansion contraction during operation If a trapeze method is used for tube support hanger brackets Shown below the minimum chain length for the two connecting chains is 914 mm to minimize any vibration that might be generated by the draft inducer assembly If these chains must be less than 914 mm then do not use the trapeze method and instead use individual chains on each tube support hanger bracket IMPORTANT When U Tube Heaters are angle mounted see Fig 19 the fan should be assembled to the higher of the two emitter tubes as shown U TUBE MODELS LINEAR MODELS 1 H 1 1 H 1 1 i RN 1 1 l 1 1 H AG Neon Lights lt Fan at highest poin
43. evA 13 Secure the upper reflector panels to the reflector spacer brackets as shown in figure 21n below I Screw through the reflector with the 10 self drilling screws into the reflector spacer bracket ll Repeat this at each hanger bracket specified in figure 21n CAUTION Due to up to 40mm expansion and contraction during operation DO NOT Side View SCREW the reflector at this bracket First Reflector Second Reflector Third Reflector ADU 40 45 only E First Overlap Position screws to the center of the spacer bracket under the 2 x 10 Self Drilling Screws upper reflector panel a s t Q Side View Position 1 is the preferred location for the securing screws if low clearance above prevents access then drill the screws in at position 2 D Fig 21n 14 Place side panels over the sides of both reflector panels between each tube support hanger bracket and at the ends of the heater Secure these in place using the side panel holder brackets and two 10 x 1 2 sheet metal screws supplied in fastenings kit See Figure 210 below Side Panel Upper Reflector n bd Side Panel Side Panel Holder Se Megi Brac
44. flashlight to make sure no foreign material has collected in the tubes and that there is no obstruction around the air intake openings Clean any foreign materials Inspect any joints to make sure they are completely sealed See also Section 13 e Venting System Disconnect vent pipe and inspect internally using a flashlight to make sure no foreign material has collected in the pipes Check the external vent cap and make sure that there is no obstruction around the exhaust openings Clean any foreign materials Inspect any joints to make sure they are completely sealed See also Section 13 e Gas lines Make sure that the gas lines are not leaking Check the gas connection to the heater for any signs of damage fatigue or corrosion If there are any signs of damage to the gas connection or leaks found in the gas piping immediately stop using the heater until the gas pipe and connections have been repaired or replaced Check that the gas lines are not bearing the weight of the heater See also Section 11 e Burner Box In order to extend the longevity of the heater the heat exchanger tube and the burner must be level Check that the burner box is level use the turnbuckle on the burner suspension eyebolt to adjust the level of the burner See also Section 9 1 e Blower wheel and housing Check that the blower wheel spins freely blow out any dust or dirt with compressed air e Electrode condition Visually check that the electrode gap is maintained
45. following figure shows the typical arrangements for concentric sidewall flues see Table 18 for 90 bend equivalent lengths The bends shown in the illustrations connecting the combustion air intake to the concentric ducts is calculated into the overall length For example a system with one additional 150 100mm concentric 90 bend can be installed with 1m 100mm flue single pipe and the combustion air single pipe as shown with 5 5m of 150 100mm straight concentric flue 8m 2 5m from Table 18 47 Components Top View Nr Supplier Description a 1 M amp G Wall Terminal 150 100mm 2 M amp G Concentric vent 150 100mm 3 M amp G Flue Single pipe 100mm Max 8m 4 M amp G Combustion Air single pipe 100mm 5 M amp G Elbow single pipe 100mm 3 shown 6 Space Ray Fresh air connector 7 Space Ray Flue connector 1 H L ns ll Tri j OS Se View x l ALTERNATIVE Use M amp G approved flexible connector For fresh air supply Above shows typical arrangement for flue to the side of the heater
46. ge IMPORTANT BEFORE CONNECTING THE GAS TO THE HEATER a Connect to the supply tank or manifold in accordance with state or local building codes Authorities having jurisdiction should be consulted before the installation is made b Check that the gas fuel on the burner rating plate matches the fuel for the application c Check that the gas supply piping has the capacity for the total gas consumption of the heaters and any other equipment connected to the line d Check that the calculated supply pressure with all gas appliances and heaters operating will not drop below the minimum supply pressure required for these heaters See Table 17 Below Table 17 Gas type Appliance Nominal Supply Maximum Minimum Supply Setting Pressure Category Pressure Supply Pressure Pressure Natural Gas G20 24 20 mbar 25 mbar 17 mbar 12 5 mbar LPG G31 3p 37 mbar 45 mbar 30 mbar 25 mbar e All gas supply lines must be located in accordance with the required clearances to combustibles from the heater as listed on the clearances label of the heater and Section 4 0 of this manual f Pipe joint compounds must be resistant to the action of liquefied petroleum gases g Tube heaters will expand contract during operation Use an approved flexible connector for connections between the rigid piping and the heater A union
47. he second hanger bracket The reflector must be able to move freely through the hanger bracket when the heater operates Failure to allow the reflector to move will result in severely distorted reflector panels Form 4420110 Sept 2010 Rev A 29 CAUTION Due to up to 40mm expansion and contraction during operation DO NOT Side View CLAMP the reflector at this bracket First Reflector oo Second Reflector Third Reflector ADU 40 45 only K irst Overlap Reflector Locking Clamp Lower Reflector 10 x 1 2 Sheet Metal Screw Fig 21k 11 Attach the reflector spacer brackets at each tube support hanger bracket using the 10 24 machine screws supplied in fastening kit See figure 211 below End View Reflector Spacer Bracket 10 24 Machine Screw Hanger Bracket Fig 241 12 Place the upper reflector panels over each of the reflector spacer brackets Repeat the same reflector positions and overlap dimensions as specified in table 14 see step 9 above To align reflectors precisely to the ends of the lower reflector hold the end cap in place against the lower reflector slide the upper reflector to rest against it See figure 21m below Align upper reflector panels flush to the end of the lower reflector panels Fig 21m gle joo Form 44201100 30 Sept 2010 R
48. illing Screws 6 QTY 2 Fig 23a h Check to ensure that the hardware is completely closed and the band is seated on the reaction block and interference pins as illustrated above Once all the heater body sections are attached make sure that the heater system is level If it is not slight adjustments can be made using the turnbuckles See Section 7 0 Band Force Bars Bolt Reaction Interference CORRECT INCORRECT Block Pins INSTALLATION INSTALLATION Fig 23b AN CAU TI O N Important NEVER reuse a coupling Always install a new coupling only and torque as per instructions above and the diagrams above Form 44201100 38 Sept 2010 Rev A 10 3 ATTACHING BURNER BOX ASSEMBLY END VIEW 7 mounting AC position Warning LIGHTS MUST FACE DOWN Failure to do so will result in overheating the ignition module and will invalidate the warranty ja Tube 76 2mm Torctite Gomm DR KI Self Drilling Screws QTY 2 Tube Connection 76 2mm Models ADL25 and ADU25 Fig 24 Radiant Tube 101 6mm Torctite Coupling n 10 Self Drilling Screws QTY 2 Tube Connection 101 6mm Models ADL30 ADL35 ADL40 ADL45 ADU30 ADU35 ADU40 ADU45 1 Place a Torctite Coupling over the end of the Radiant Tube refer to Section 10 2 Tube Coupling Details Assemble the Burner Box to the Radiant Tube ensuring that it engages f
49. ith the dimensions stated because the side panels provided with the heater are designed to cover the entire length of the reflectors and therefore if the location of the reflectors does not match these dimensions then the side panels will not fit See table 14 and figure 21j below Table 14 Model Dimension First Reflector First reflector Second Second Third from first length overlap Reflector reflector Reflector hanger to end Length overlap Length of reflector ADU25 76mm 2438mm 116mm 2438mm N A N A ADU30 35 214mm 3035mm 396mm 2540mm N A N A ADU40 45 214mm 3035mm 182mm 2540mm 182mm 1511mm First Reflector Second Reflector Third Reflector ADU 40 45 only pre I gt lt First Hanger bracket to First Overlap gt Second Overlap the end of the reflector ADU 40 45 only Side View Fig 21 10 With the lower reflector panels in place secure the reflectors to the hanger brackets on both sides of the reflector as shown in figure 21k L From the underside of the hanger bracket drive in the sheet metal screw until the tip is just through the reflector panel ll Position the Reflector Locking Clamp over the screw and continue to drive the screw until the reflector is secured in place lll Repeat this at each hanger bracket specified in figure 21k A CAUTION CRITICAL ASSEMBLY DETAIL The reflector MUST NOT be clamped at t
50. ket Screws 12mm space for end cap gt lt Side Panel Holder A Bracket Fig 210 Form 4420110 Sept 2010 Rev A 31 15 Attach burner box and fan assembly as shown in Sections 10 3 and 10 4 16 Tighten all screws securing clamps and brackets installed earlier Place end reflector caps and secure using screws supplied in fastening kits as shown in Fig 21p below Reflector Head End Cap typical installation for Foot End Cap at opposite end of heater Sheet Metal Screws evenly spaced 6 places Fig 21p 17 Make all final gas and electric connections as outlined later in the instructions 10 1 LINEAR HEATER ASSEMBLY A CAUTION UT HAZARD Sheet metal parts particularly reflectors and vent have sharp edges Always use gloves when handling Failure to do so may result in death serious injury or property damage See heater dimensions and assembly overview Sections 8 0 and 8 1 for each Linear configuration It is recommended to read the all the instructions carefully before proceeding with the installation During field assembly of the heater body sections the recommended procedure is as follows 1 Determine the actual layout of the system first before hanging heater sections Consideration must also be taken for flue pipe fresh air ducting gas piping clearances to combustibles etc before hanging heater 2 Install the heater suspension chains or alternate methods outlined in
51. l connector and the grey HT ignition spark flame sensor lead from the Ignition Control 2 Unscrew the M3 screw securing the Ignition Control to the Control Valve 3 Slide out the Ignition Control 18 5 REMOVING AIR SWITCH Fig 42 1 After opening the control box door remove the Air Tube Assembly from the Air Switch pressure connection marked H 2 Disconnect the three electrical leads from the Air Switch by gently pulling the connectors using pliers 3 Unscrew the two No 8 x 12 self tapping screws securing the Air Proving Switch to the floor of the Control box and lift out with the electrical leads attached 4 Remove the Air Switch and remove the restrictor from the Air Switch connection marked L When installing a replacement Air Switch take care to connect the electrical leads in accordance with the wiring diagram shown in Section 18 5 and replace the restrictor on the pressure connection marked L The appliance will not function unless this restrictor is in place Form 4420110 Sept 2010 RevA 57 18 6 REMOVING GAS VALVE AND MANIFOLD ASSEMBLY Fig 43 1 After opening the control box door disconnect the 12 way Molex electrical connector Disconnect the grey HT ignition spark flame sensor lead from the ignition module Unscrew the two M4x25 setscrews from the burner bracket and remove the burner clamp Unscrew the burner and slide it away from the valve Unscrew the
52. le tub Pressure Test Nipple edno ube LEFT Gas In Pressure Test Nipple RIGHT Gas Out O O Manometer Control End View Tubing Pressure Govenor Digital or Water Adjuster Column Manometer scale 0 100mbar Control Front View access panel not shown 44 TO CHECK THE GAS SUPPLY PRESSURE a Unscrew the sealing screw two turns of the LEFT Gas IN Control Valve test nipple and connect the free end of the manometer tube permanently connected to the manometer test nipple inside the side panel of the control box to this test nipple See Fig 29 Close the control box door and secure with the two toggle latches b Ignite the appliance burner by switching on the electricity supply to the appliance and check that the manometer reading is as stated below for the gas type the appliance is adjusted for see the Data Label affixed to the Control Box door See Table 17 for gas supply pressures c Switch off the electricity supply to the appliance open the control box door and remove the manometer tube from the LEFT Gas IN control valve test nipple Screw in the test nipple sealing screw TO CHECK THE BURNER SETTING PRESSURE a Unscrew the sealing screw two turns of the RIGHT Gas OUT Control Valve test nipple and connect the free end of the manometer tube permanently connected to the manometer test nipple inside the side panel of the control box to
53. m hanger to burner Side Panel 2438 suspension bracket 4 each 4 each 2489 ly 2489 i 765 di 765 s Side View M T W m D Side Panel 160 182 i na 2 each overlap e 182 overlap Models 452K 5743 gt ADU40 from end of tube ADU45 to hanger U Bend I s E E Bottom View l l 305 711 Burner bi t Box Z 1 Fan JO 101 6 x 3048 Assembly Gem Radiant Tube Hanger Bracket lt 254 Pan 4 each 4 each end of U bend to reflector 160 from end of reflector to hanger End View CRITICAL ASSEMBLY DETAIL Spacing between the hanger brackets MUST be the dimensions shown 12mm to allow the fixed length side closure panels to be installed with room for movement during expansion and contraction of the heater during cycles Form 44201100 14 Sept 2010 RevA HEATER ASSEMBLY OVERVIEW U TUBE CONFIGURATIONS 7 1 4aBuey o Jeng woy SUOIJONJJSUI UO e E SUI p j ie p JOJ 0 0L UONJ9S OJ Joo DLC 40 99 J94 0 JOUING WO4 eve depo 10494491 a uleyd TR vo uolsuadsns L xog Jeuing uoisuedsns O W lo 89g jop Deo JoploH Isueg spis Dee xog Jeuing o91o L A quessy b joued opis TS Ge i N S Os A yoee z Ms ZLGv X sanl z92 ue yoee jeyoelg io6ueH psu9xJoN fuoddns eqny eyoy pug syoyejnqun L E a Ce 1e91d SINN X H AUS N San due yog N Jeoeds Joel SMOJIS ew N O Se V uleld
54. n Unit Airflow 52BTFR ADL ADU 40 amp 45 only 1 2 4260132 _ Gasket 1 3 42741170 Air Restrictor Plate 76 2mm dia opening 1 4 4260370 Connector for 76 2mm dia tube 1 5 4260371 Connector for 101 6mm dia tube 1 6 44200010 Flue Screen Outlet Plate 103 x 113mm accessory 1 7 4267061 M6 x 16mm Hex Head Setscrews 6 7a 4267266 M6 Spring Lockwashers 6 Form 4420110 Sept 2010 RevA 63 Gas Fired Products UK Ltd Chapel Lane Claydon Ipswich Suffolk IP6 OJL England Phone 01473 830551 Fax 01473 832055 E mail info spaceray co uk www spaceray com uk Form 44201100 64 Sept 2010 RevA
55. ng Inl etor era ged E EENS hiai ia Raih ta 56 Removing Ignition Control aaa aaa aaa aaa aaa aaa 57 Removing Air Switch ve Removing Gas Valve and Manifold Assembl u u u 58 Removing Neon Indicator eee a A a dida id nae Removing Air Inlet Plate Removing the Fan gt lt ie aa aki geed ek dd aie teenie i ee ee hele Conversion Instructions aaa naa aaa kaaa aaa nadan Installation Data Replacement Parts Guide 1 0 SAFETY This heater is a self contained infrared radiant tube heater Safety information required during installation and operation of this heater is provided in this manual and the labels on the product The installation service and maintenance of this heater must be performed by a contractor qualified in the installation and service of gas fired heating equipment All personnel in contact with the heater must read and understand all safety information instructions and labels before operation The following symbols will be used in this manual to indicate important safety information Warning instructions must be followed to prevent or avoid hazards which A WARN N G may cause serious injury property damage or death Caution instructions must be followed to prevent incorrect operation or ANCAUTION installation of the heater which may cause minor injury or property damage 2 0 INSTALLER RESPONSIBILITY
56. nversion kit onto the Data Label adjacent to the headings Adjusted For and Setting Pressure to cover the original gas adjustment label 2H G20 20mbar d Carry out checks in accordance with Section 11 0 of this manual to ensure correct supply pressure relative to the gas type being used CONVERSION FROM CAT 3P LPG TO CAT 2H Natural Gas a Remove the Injector from the Injector Fitting see Section 18 3 and replace it with the alternative Injector supplied with conversion kit Check that the size reference marked on the Injector agrees with that listed in the Technical Data table Section 5 0 for the appliance model in question b Remove the pressure governor cap from the integral pressure governor of the Control Valve and unscrew the adjuster counter clockwise to increase the gas pressure check supply and manifold pressure in accordance with Section 11 0 Replace the pressure governor cap c Affix the gas adjustment label 2H G20 20mbar supplied with conversion kit onto the Data Label adjacent to the headings Adjusted For and Setting Pressure to cover the original gas adjustment label 3P G31 37mbar d Carry out checks in accordance with Section 11 0 of this manual to ensure correct supply pressure and setting pressure relative to the gas type being used G20 Natural Gas 20 0 INSTALLATION DATA Date of of Heaters in Installation System Serial No N Natural Gas Model L Propane G
57. o toggle latches FLAME SUPERVISION a To check the operation of the flame supervision equipment run the appliance normally turn off the gas supply at the gas isolation valve and observe that the amber neon indicator remains illuminated b After a purge period of 10 seconds minimum the solenoid valves and the ignition spark electrode will be re energized and with the gas still turned off the ignition control will go to lockout condition after a further 12 seconds maximum Amber neon indicator extinguished c Switch off the electricity supply to the appliance for a period of 10 seconds before attempting to re ignite the burner see Section 14 Form 44201100 42 Sept 2010 RevA 12 0 ELECTRICAL CONNECTIONS AWARNING ELECTRIC SHOCK HAZARD Disconnect electrical power and gas supply before servicing This appliance must be connected to earth Failure to do so may result in death or serious injury a The electrical wiring to this heater must be installed in accordance with the latest or current National Regulations and any Local Regulations which apply Electrical supply 230V 50Hz 125W Current rating 0 55 Fuse externally 3A b Twin core and earth PVC covered flexible supply cable 0 5mm2 to National or Local standard specification must be used with connection made as follows Single Heaters per Thermostat connection diagram E __GREEN YE
58. of tube Note Refer to the table below for the number of turbulators required for each heater model Table 15 MODEL Turbulator Sections Number ADL 25 65mm x 572mm 6 ADL 30 90mm x 610mm 9 ADL 35 90mm x 610mm 4 ADL 40 90mm x 610mm 8 ADL 45 90mm x 610mm 4 LINEAR MODEL HEATERS N ZN On Bottom View N Turbulators at Fan End Ka insert in flat position a 65mm wide x 572mm long Radiant Tube b 90mm wide x 610mm long a 76 2mm b 101 6mm Fig 22d 7 Position the lower reflector panels over the tube support hanger brackets Arrange the reflector panels to the dimensions shown in section 8 0 Note The reflectors MUST be positioned in accordance with the dimensions stated because the side panels provided with the heater are designed to cover the entire length of the reflectors and therefore if the location of the reflectors does not match these dimensions then the side panels will not fit See table 16 and figure 22e below Table 16 Model A R1 01 R2 02 R3 03 R4 04 R5 ADL25 76 3035 178 3035 178 3035 368 610 N A N A ADL30 35 214 3035 127 3035 127 3035 195 610 N A N A ADL40 45 214 3035 127 3035 127 3035 127 3035 55 610 All Dimensions in mm Form 44201100 34 Sept 2010 RevA Side View First Reflector R1 Second Reflector R2 Third Reflector R3 Fourth Reflector R4 Fifth Reflector R5 flog H L H
59. or at this bracket CLAMP the reflector at this bracket First Reflector R1 Second Reflector R2 Third Reflector R3 Fourth Reflector R4 Fifth Reflector R5 ra First Overlap Position screws to the center of D the spacer bracket under the 2 x 10 Self Drilling Screws upper reflector panel d if Nat Side View Position 1 is the preferred location for the securing screws if low clearance above prevents access then drill the screws in at position 2 Fig 22i Form 44201100 36 Sept 2010 RevA 12 Place side panels over the sides of both reflector panels between each tube support hanger bracket and at the ends of the heater Secure these in place using the side panel holder brackets and two 10 x 1 2 sheet metal screws supplied in fastenings kit See Figure 22j below Side Panel Upper Reflector Side Panel Side Panel Holder Te Bracket S rews O 12mm space for end cap S P gt lt I Side Panel Holder B Bracket Fig 22 13 Attach burner box and fan assembly as shown in Sections 10 3 and 10 4 14 Tighten all screws securing clamps and brackets installed earlier Place end reflector caps and secure using screws supplied in fastening kits as shown in Fig 22k
60. p G Combustion Air single pipe 100mm 5 M amp G Elbow single pipe 100mm 3 shown 6 SpaceRay Fresh air connector o 7 SpaceRay Flue connector Section A A a J A A H Si 140mm SE ou ALTERNATIVE Use M amp G approved 4 flexible connector For Z fresh air supply I m Fig 36 165 TypeCs When fresh air for combustion and the flue outlet are from different pressures zones as shown in figure 34 the flue outlet and the fresh air intake must not be on surfaces that are 180 degrees apart The acceptable configurations are those shown in figure 34 in combination with the maximum lengths listed on Table 18 Form 4420110 Sept 2010 Rev A 49 16 6 Type C fresh air connector The connectors for the Type C fresh air are supplied as an accessory The installation steps for the Type C connector are shown in figure 38a below Step 1 Remove 3 x M6 Nuts Step 2 Unscrew pressure test point from inside cabinet Leave air plate in place Do not unscrew center pressure test point Step 3 Remove air inlet O I IS Step 4 Attach with 3 x M6 Nuts Step 5 Insert pressure
61. r to reduce the Supply Pressure below 60mbar if required Fig 26 Form 44201100 40 Sept 2010 Rev A Fig 27 Alternate Supply Locations Adaptor R 1 2 male H HI a wn i m Es l i lar d HB8 mi d v i Ki Control Box I D Dy x l NS a D d D h M t ere Adaptor R 1 2 female END VIEW SIDE VIEW INCORRECT POSITIONS lt gt EE m 4 Da lt lt Movement Movement WRONG WRONG Fig 28 Radiant tube heaters will expand and contract during operation Therefore it is essential to provide a flexible metallic hose which must conform to national or Local Regulations to connect the appliance to the gas supply Minimum size to be 1 2 12 7mm bore The gas pipe flexible hose and connections must be self supporting The gas pipe work must not bear any of the weight of the heater or any other suspended assembly A WARN N G Do not use an open flame of any kind to test for leaks 11 1 INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION CHECKING GAS PRESSURES a Switch off the electricity supply to the appliance b Con Air Fig 29 Form 4420110 Sept 2010 Rev A nect a manometer to the test nipple protruding from the rear panel of the Control Box adjacent to the nlet Adaptor See Fig 29 Open the Control Box door after releasing the two toggle latches Test Nipp
62. resemble the flue with headaches dizziness and nausea If you experience these signs GET FRESH AIR IMMEDIATELY Have the heaters serviced as soon as possible and check the ventilation in the house These heaters are designed for non residential space heating applications and may operate with the use of either Natural Gas or Liquid Propane LP Gas Check the heater s nameplate to determine the correct gas type before proceeding with installation IF YOU SMELL GAS FOR YOUR SAFETY DO NOT try to light any appliance DO NOT touch any electrical switch DO NOT use any telephone in your building DO NOT store or use petrol or other flammable t IMMEDIATELY call your gas supplier from a neighbour s vapors and liquids in the vicinity of this or any telephone Follow the gas supplier s instructions If you other appliance cannot reach your gas supplier call the fire department IMPORTANT SAVE THIS MANUAL FOR FUTURE REFERENCE Gas Fired Products UK Ltd Chapel Lane Claydon Ipswich Suffolk IP6 OJL England Phone 01473 830551 Fax 01473 832055 E mail info spaceray co uk www spaceray com uk Form 44201100 Sept 2010 RevA SECTION TABLE OF CONTENTS DESCRIPTION PAGE 1 0 2 0 3 0 4 0 5 0 6 0 7 0 7 1 8 0 8 1 9 0 9 1 9 2 10 0 10 1 10 2 10 3 10 4 11 0 11 1 12 0 13 0 14 0 15 0 16 0 17 0 18 0 18 1 18 2 18 3 18 4 18 5 18 6 18 7 18 8 18 9 19 0 20 0
63. rol Box door after releasing the two toggle latches 2 Disconnect the grey HT ignition flame sensor lead and the green yellow earth lead from the electrodes by gently pulling the connectors using pliers 3 Unscrew the M6 x 16 setscrew securing the electrode carrier to the Control Box and remove the Electrode Assembly 4 Remove any foreign matter from the Electrode tips and check that the spark gap is 3 5mm If the Electrode rods are badly oxidized replace the electrodes 5 Upon re assembly ensure that the HT lead and earth lead connectors are securely attached to the Electrodes Form 4420110 Sept 2010 RevA 55 18 2 REMOVING MAIN BURNER Fig 39 1 Open the control box door unscrew the two M4 x 25 setscrews from the Burner Bracket and remove the Burner Clamp 2 Unscrew the Burner from the Injector Fitting w Lift the burner out of the Control Box 4 Clean by use of a stiff brush to remove any deposits 18 3 REMOVING INJECTOR Fig 40 1 Remove the Burner as described at above Unscrew the Injector from the Injector Fitting using a spanner whilst retaining the Injector Fitting with a second spanner 2 Inspect the Injector and clean as necessary with a soft bristle brush DO NOT DAMAGE THE INJECTOR ORIFICE BY USE OF SOLID OBJECTS Form 44201100 56 Sept 2010 RevA 18 4 REMOVING IGNITION CONTROL Fig 41 1 Disconnect the 12 way Molex electrica
64. ses by a qualified installer A WARNING SUSPENSION HAZARD Burner must be secured to the mounting flange with nuts All materials used to suspend the heater must have a minimum working load of 52kg All S Hooks must be crimped closed Never use the heater to support a ladder or other access equipment Failure to do so may result in death serious injury or property damage Various means of suspending the heater can be used See the following drawings for typical examples Use only noncombustible materials for suspending hangers and brackets b Linear Tube Heaters should be suspended to provide a slope of 0 25 degree up to the fan 25 to 50mm The appliance should be located with respect to building construction and other equipment to permit access to the appliance for servicing etc U Tube Heaters should be suspended horizontally along the length d Turnbuckles can be used with chains to allow leveling of the heater All S hooks and eye bolts must be manually crimped closed by the installer e For suspending the appliance it is recommended that suitable protected welded chain 3mm x 65 links per m or 8mm min mild steel drop rods and suitable brackets are used Attach the chains or drop rods to the hanger brackets where shown providing at least 5mm closed link hooks are used chains may be attached directly to the hanger brackets f Heaters subject to vibration must be provided with vibration isolating hang
65. should be installed before the control box inlet An approved shut off valve should be installed within 1 8m of the union h The gas pipe flexible hose and connections must be self supporting The gas pipe work must not bear any of the weight of the heater or any other suspended assembly i This appliance is equipped with a step opening combination gas valve The maximum supply pressure to the appliance is 60 mbar If the line pressure is more than the maximum supply pressure then a second stage regulator which corresponds to the supply pressure must be used j After all gas connections have been made make sure the heater and all gas outlets are turned off before the main gas supply is turned on slowly Turn the gas supply pressure on and check for leaks k Ifa 2nd stage regulator is used the ball valve down stream in the supply line must be closed when purging the gas lines to prevent gas seeping through it If initial gas pressure is higher than 60 mbar the redundant combination gas valve is designed to lock out Pressure build up in the supply lines prior to the heater must be released before proper heater operation A WARN N G Do not use an open flame of any kind to test for leaks KEY DIMENSIONS AND COMPONENTS OF THE GAS CONNECTIONS Approved I Gas Supply Flexible Connector Piping p Ss Manual Gas Shut Off Valve N Sediment Trap Drip Leg 36 to 43cm Scm Max Second Stage Regulator with Displacement Vent Leak Limite
66. son and at any time excessive accumulation of dust and dirt is observed Maximum heating efficiency and clean combustion will be maintained by keeping the heater clean It is essential that at least once a year preferably before the heating season a qualified person service the appliance In exceptionally dirty conditions more frequent servicing may be desirable IMPORTANT a Donot rest anything especially ladders against the appliance Form 4420110 Sept 2010 RevA 51 b Gas and Electricity supplies must be isolated before commencing servicing work or replacement of components c On completion of a service fault finding task which has required the breaking and remaking of electrical corrections the following checks using a multi meter must be made 1 Earth continuity check 2 Polarity check 3 Resistance to earth check The contractor shall check the following during periodic maintenance e Clearances to combustibles Check that clearances are being maintained Make sure there are no flammable objects liquids or vapors near the heater See also Section 4 0 e Reflectors Reflectors should be kept clean at a minimum blow off the reflectors Dirty reflectors will reduce heat output e Heat exchanger tubes Inspect the heat exchanger tubes to make sure they are not cracked sagging or showing signs of fatigue e Combustion air intake Disconnect combustion air intake from the control box and inspect internally using a
67. t Neon Lights Neon Lights Neon Lights Neon Lights Horizontal Mounting Angle Mounting Horizontal Mounting Horizontal Mounting with Angle Mounting 30 MAX alternate trapeze 30 MAX hanging method Fig 19 Form 44201100 22 Sept 2010 RevA 9 1 BURNER BOX SUPPORT DETAILS 1 The Burner Box must be supported with a welded chain after overall heater suspension is complete This is to prevent burner from sagging Assemble bracket and turnbuckle to inlet end of burner as shown Welded Chain Turnbuckle G Adjust turnbuckle Bracket i to level control en io SY pva Deg M6 Nut amp Washer Angle up to fan 50mm over the Level Lights must face down ECH SEH Fig 20 2 Adjust the turnbuckle until control box is level Use a leveling device to verify A CAUTION Failure to install the burner box suspension Linear heaters must be angled up from chain vertically will void the manufacturers the burner box Failure to do so may warranty result in overheating of internal components resulting in equipment failure 9 2 USER INSTRUCTION LABEL The User Instruction label shown below is supplied with each heater Affix this label adjacent to low level user controls such as thermostats time clocks or control panels OVERHEAD RADIANT HEATER OPERATING INSTRUCTIONS TURN ON GAS SUPPLY SET TIME SWITCHES OR THERMOSTATS TO DEMAND HEAT SWITCH ON ELECTRICI
68. test point Type C fresh Air plate Gasket Step 6 Secure pressure air connection test point with nut inside cabinet Fig 36a 14 0 LIGHTING AND SHUTDOWN INSTRUCTIONS a e Ensure that the Control Box lid is closed and secured with the two toggle latches The heater will not operate with the door open Turn on the gas supply to the appliance Set any time switches or thermostats to demand heat Switch on the electricity supply to the appliance The red neon indicator and amber neon indicator will be illuminated The burner should ignite within 20 seconds Both red and amber neon indicators will remain illuminated Failure to ignite will result in the ignition controller going to lockout condition The red neon indicator will remain illuminated The amber neon indicator will be extinguished If lockout occurs switch off the electricity supply to the appliance wait for 3 minutes before switching on the electricity supply to the appliance to repeat the ignition sequence If the appliance fails to ignite after a second sequence switch off the electrical supply to the appliance and call the service engineer If gas failure occurs after successful ignition the appliance will attempt one re ignition before going to lockout condition To shut down the appliance for short periods of time switch off the electricity supply to the appliance To shut down the appliance for longer p
69. this test nipple See Fig 29 Close the control box door and secure with the two toggle latches b Ignite the appliance burner by switching on the electricity supply to the appliance and check that the manometer reading is as stated below for the gas type the appliance is adjusted for see the Data Label affixed to the control box door See Table 17 for gas setting pressures c Inthe event that the burner setting pressure is incorrect switch off the electricity supply to the appliance and remove the cap from the integral pressure governor for the Control Valve see Fig Close the control box door and switch on the electricity supply to the appliance to ignite the burner Remove the plug from the control box door and insert a suitable screwdriver through the exposed hole in the box to locate the governor adjusting screw Adjust the pressure by turning the pressure governor adjusting screw clockwise to increase or anti clockwise to decrease the burner setting pressure See Fig 30 Remove hole plug Use screwdriver for pressure adjustment at govenor Fig 30 d Upon obtaining the correct burner setting pressure switch off the electricity supply to the appliance remove the screwdriver replace the plug into the upper surface of the control box door and open the door Remove the manometer tube from the RIGHT Gas OUT Control Valve test nipple and screw in the test nipple sealing screw Close the control box door and secure with the tw
70. tion of the seal around the Control Box door and replace as necessary IMPORTANT The appliance will not function unless the seal around the control box door is sound and the door secured with the two toggle latches e Flue Pipes For flued appliances it is important that periodic sweeping of the flue is carried out according to the National or Local regulations in force e Auxiliary Controls Room thermostats time switches frost thermostats etc should be checked to ensure correct functioning and are set to the user requirements e Re assemble and Commission Re assemble the appliance in reverse order and commission in accordance with the instructions contained in Section 15 0 Form 44201100 52 Sept 2010 RevA 17 0 TROUBLESHOOTING GUIDE PI S Lt paljeysul aq PINOYS xoq 041409 Y SIMEUJO XO olluo2 Y 0 JOMOd Y Ups pue AJLA SEG HO nus xoq onuoo u pisu Bunoous lqno1 usyM JON Bed 1X9U y uo p nunuos Bunoous lqnoi l 53 Sat E gt lt N g gt
71. uey Ionuoo au u uo fejs xoq O UOD su K ON 1 2 16 inss id sef K ON Joyeoipul uoau sequie uie nsdn S AI8A yo S xoq Ionuoo y 0 au s op dnpejs ynys se6 ije uo uny Aiddns se su 49D u Jaye spuoo s gg abed enotaaid y wou p nunuos Dunoousagno1t Form 44201100 Sept 2010 RevA 54 18 0 REPLACING PARTS AWARNING ELECTRIC SHOCK amp EXPLOSION HAZARD Disconnect electrical power and gas supply before servicing Failure to do so may result in death or serious injury Only use genuine Space Ray replacement parts Parts are available from the factory for replacement by a licensed person Refer to the Replacement Parts Guide in Section 21 0 for all replacement parts IMPORTANT Disconnect gas and electricity supplies to the appliance before carrying out any repair work This work can be carried out at high level using a purposes designed access tower but it is preferable that this work should be carried out at ground level 18 1 REMOVAL OF ELECTRODES 3 5mm Spark Gap Fig 38 This range of radiant tube heaters employs a single probe electrode system whereby both the spark generation and flame supervision operations are carried out via a common electrode The second electrode provides the earth path for the ignition spark The two electrodes are identical therefore either lead grey HT or green yellow earth may be connected to either electrode 1 Open the Cont
72. ully into the Torctite Coupling and is positioned vertically Tighten the bolts of the Torctite Coupling to secure the Burner Box to the Radiant Tube taking care to support the Burner Box in line with the axis of the tube 2 Attach the burner box to the support chain See Section 9 1 for details 10 4 ATTACHING FAN ASSEMBLY T Coupling Radiant Tube 76 2mm ocr Screws QTY 2 Tube Connection 76 2mm Models ADL25 and ADU25 Fig 25 Torctite Coupling Radiant Tube 101 6mm Tube Connection 101 6mm Models ADL30 ADL35 ADL40 ADL45 ADU30 ADU35 ADU40 ADU45 10 Self Drilling Screws QTY 2 1 Place a Torctite Coupling over the end of the Radiant Tube refer to Section 10 2 Tube Coupling Details Assemble the Fan Assembly to the Radiant Tube and position the fan outlet pointing upwards for flueless applications Tighten the bolts of the Torctite Coupling to secure the Fan Assembly to the Radiant Tube taking care to support the Fan Assembly in line with the axis of the tube Form 4420110 Sept 2010 RevA 39 11 0 GAS CONNECTIONS AND REGULATIONS AWARNING FIRE AND EXPLOSION HAZARD Tighten flexible gas hose and components securely Flexible metal gas hoses must be installed without any twists or kinks in them The hose will move during operation of the heater and it can crack if it is twisted Failure to do so may result in death serious injury or property dama
73. ut of the system first before hanging heater sections Consideration must also be taken for flue pipe fresh air ducting gas piping clearances to combustibles etc before hanging heater 2 Install the heater suspension chains or alternate methods outlined in Section 9 Typical Suspension Methods Space the suspension points according to the hanger bracket spacing dimensions see section 7 0 for each heater Use spanning steel work if necessary to position suspension points Note Suspension points are fixed along the length of heater to accommodate the side panels 3 Space the hanger brackets according to the dimensions shown in the figures below for the first tube section Note The distances are measured from center of the holes of each support hanger bracket See figure 21 below for ADU25 and Figure 21a for ADU30 35 40 45 Note for ADU25 install all three hanger brackets Tube Clamping Detail A ADU25 Tube Body Assembly U Bolt Clamp U Bolt Clamp with clearance snug fit Fan Tube i Burner Tube L ig EI clearance D A E Fa 5 16 18 Nuts Hanger Bracket Weld seam to the 5 16 18 Nut 2 each leg bottom of tubes 1 each leg Burner Tube Fan Tube 2099mm 2099mm Tube Clamping Detail B U Bolt Clamps snug fit 152mm o ea Burner Tube Burner attaches to this end of the tube P ee S d Pau F Red 7 Ce 5 16 18 Nut Hanger Bracket Weld seam to the 5 16 18 Nut 1
74. vacuated above the radiant heaters if possible near the ridge by means of exhaust mixture opening s vents c Where the exhaust mixture opening s can be closed it shall only possible to operate the radiant heaters when they are open d The maximum horizontal distance between a radiant heater and a vent opening shall be 6 six times the vent height in the case of wall openings 3 three times the vent height in the case of roof openings VENTILATION BY MECHANICAL EVACUATION a Ventilation by mechanical evacuation is sufficient if 10m h of exhaust air per kW of operating heat input are ventilated out of the installation room b The air products of combustion mixture must be evacuated above the radiant heaters using fan s c Itshall only be possible to operate the radiant heaters whilst the exhaust airflow is proven d The maximum horizontal distance between a radiant heater and a fan shall be 6 six times the fan mounting height in the case of wall openings 3 three times the fan mounting height in the case of roof openings e Total minimum proven ventilation airflow in m h will be Total installed kW input X 10 Note Mechanical exhaust air openings must be positioned such that the burner stability of the nearest appliance is unaffected VENTILATION BY NATURAL AIR CHANGE Gas fired radiant heaters may be operated without any special exhaust system if the exhaust gases are discharged to the outside atmosphere by a suffi
75. ystem 5 Suspend the hanger brackets for the remaining section of tube raise the tubes into position and join the tube sections together using Torctite couplings as described in Section 10 2 Tube Coupling Details Fasten the tubes to the hanger bracket See figures 22a 22b and 22c for details of the assembly sequence and hanger bracket attachment method Refer to section 8 0 for the dimensions of the hanger bracket spacing ADL Second Tube Section Assembly First tube section 2489mm Fig 22a Install each tube individually and tighten torctite couplings U Bolt Clamp P ea snug fit LA L Le F Ze J Hanger Bracket Weld seam to the 5 16 18 Nut bottom of tubes 1 each leg Typical attachment method for every hanger bracket Fig 22c Form 4420110 Sept 2010 RevA 33 6 Insert turbulators where required into the tube sections as described below A WARNING POISONOUS GAS AND SOOT HAZARD The heater must be assembled with the correct number of turbulator sections and tube length for the rated heat input The turbulators must be installed in the tube sections as shown below Failure to do so may result in death serious injury property damage or illness from Carbon Monoxide poisoning IV Assemble the turbulators together by interlocking the slotted ends V Slide these into the tubes at the end of the heater as shown for Linear Models VI Align the turbulator end flush with end
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