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AS 4643-2007

[Available Superseded]

Overhead radiant tube gas heaters

Specifies the uniform minimum requirements for manufacturers, designers, regulatory authorities, testing laboratories and similar organizations for the safety, performance and use of overhead radiant tube gas heaters intended for use with natural gas, town gas, tempered liquefied petroleum gas and liquefied petroleum gas.
Published: 29/03/2007
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Table of contents
Cited references
Content history
Table of contents
About this publication
1 Scope and definitions
1.1 Scope
1.2 Definitions
2 Design and construction
2.1 General
2.1.1 Individual component or specification study
2.1.2 Physical inspection
2.1.3 Certification of safety components
2.1.4 Programmable electronic systems (PES)
2.1.5 Manual shut off valves
2.1.6 Classification of safety shut off valves
2.1.7 Requirements for electrical components and their installation
2.1.8 Sharp edges
2.1.9 Continuation of satisfactory operation
2.1.10 Protection of vitreous enamel
2.1.11 Means of support
2.1.12 Compliance in alternative forms
2.1.13 Locking means for adjusting devices
2.1.14 Alteration of programmed ignition
2.1.15 Locking of dampers
2.1.16 Means for gas pressure adjustment Means to allow the gas pressure to be measured Pressure test points
2.1.17 Protection of bearings
2.1.18 Construction of primary aeration controls
2.2 Materials and Standards
2.2.1 Suitability of materials and finishes
2.2.2 Materials in contact with gas
2.2.3 Materials containing asbestos
2.2.4 Materials used in appliances
2.2.5 Zinc based alloys
2.2.6 Components to be placed in a flame
2.2.7 Protection of aluminium tubing
2.2.8 Construction of primary aeration controls
2.2.9 Outdoor appliances—protection against corrosion
2.2.10 Compression fittings
2.3 Electrical systems
2.3.1 Accessibility to electrical components
2.3.2 Connection of electrical components
2.3.3 Plug and socket connections
2.3.4 Protection against accidental contact
2.3.5 Provision of electrical lead and plug
2.3.6 Protection of controls for and wiring—outdoor installation
2.3.7 Details of bearings
2.4 Installation requirements
2.4.1 Fixing of gas inlet connection
2.4.2 Gas inlet connection thread
2.4.3 Access to gas connection
2.4.4 Means for mounting
2.5 Maintenance requirements
2.5.1 Special tools
2.5.2 Dismantling and replacement
2.5.3 Insertion and removal of gas injectors
2.5.4 Assembly and attachment of handles, dials and pointers
2.5.5 Accessibility for adjustment
2.5.6 Accessibility for replacement
2.5.7 Threaded connections
2.5.8 Inaccessible nuts or bolts
2.6 Pressure regulators
2.6.1 Provision of pressure regulators
2.6.2 Positioning of regulators
2.7 Gas controls and flame safeguards
2.7.1 Accessibility by the user
2.7.2 Accidental changes of setting
2.7.3 Indication of function
2.7.4 Fitting of safety shut off system
2.7.5 Main burner automatic shut off valves
2.8 Combustion air supply and controls
2.8.1 Combustion air supply equipment
2.8.2 Combustion air flow proving interlock
2.8.3 Prevention of combustion air backflow
2.9 Ignition, pilots and main burners
2.9.1 Pilot burner shut off
2.9.2 Viewing of burner flames
2.9.3 Proving ignition
2.9.4 Support of pilot burners, igniters and flame sensing devices
2.9.5 Location of burner mixing tubes
2.9.6 Burner supports
2.9.7 Fixing of gas manifolds
2.9.8 Protection of ports and injectors
2.9.9 Restriction on gauze over primary air ports
2.9.10 Aeration adjustments for universal LPG appliances
2.10 Flueing requirements
2.10.1 Design of air entry and combustion product discharge
2.10.2 Design of flue connection—blockage
2.10.3 Design of flue connection—compatibility
2.10.4 Design of flue connection—engagement
2.11 Markings
2.11.1 Label related to domestic use
2.11.2 Markings on packaging—installation
2.11.3 Gas type label
2.11.4 Gas type colour code
2.11.5 Identification of injectors
2.11.6 Direction of rotation of fans
2.11.7 Other permanent markings on appliances
2.11.8 Markings of doors and covers
2.11.9 Marking of parts that may affect combustion
2.12 Instructions
2.12.1 Installation Instructions attached to the appliance
2.12.2 Operating Operating instructions supplied with appliance Abnormal operation, maintenance schedule, service and replacement parts Warning statement
2.12.3 Servicing Servicing instructions remaining with the customer
3 Preliminary tests - Line gases
3.1 General requirements
3.1.1 Nominal gas consumption
3.1.2 Test gases
3.2 Preparation for testing
3.2.1 Electrical safety requirements
3.2.2 Setting up the appliance for testing
3.2.3 Appliance regulator not to be removed during testing
3.2.4 Protection from accidental draughts
3.2.5 Prevention of gas rate variation
3.2.6 Gas pressure and gas volume test equipment
3.3 Gas leakage
3.3.1 Gas tightness
3.3.2 Gas tightness after testing
3.3.3 Control of bleed lines
3.4 Gas consumption
3.4.1 Tolerance on determined gas consumption
3.4.2 Determined gas consumption of continuously burning pilots
3.5 Gas pressure regulators
3.5.1 Pressure regulator performance
3.6 Ignition and flame safeguard systems
3.6.1 All ignition and flame safeguard systems Aerated pilots Ignition at reduced pilot rate Multi-port pilots Holding time for thermoelectric flame safeguard Flame safeguard Flame travel at ignition Cessation of ignition spark Commencement of ignition after purge period Proving of start flame Flame safeguard system—self check Flame failure Flame establishment period—intermittent pilot Flame safeguard system—shut off time
3.6.2 Atmospheric burners with automatic burner ignition systems — additional requirements Start flame establishment period Gas flow rate at ignition Start flame proving period—gas flow rate exceeds Clause Number of reignition attempts
3.6.3 Forced or induced draught burners with automatic burner ignition systems—additional requirements Start flame establishment period—energy release Start flame proving period—gas flow exceeds Clause Number of reignition attempts after flame failure Prepurge before ignition Proving of main flame—interrupted pilot Flame safeguard relays—intermittent pilot
4 Tests using limit pressures
4.1 General
4.2 CO/CO2 ratio limits of any independent surface combustion burner—Underload
4.3 CO/CO2 ratio limits of any independent burner—Overload
4.4 CO/CO2 ratio of permanent pilots—Overload
4.5 CO/CO2 ratio flue back pressure and blocked flue
4.6 Flame abnormality
4.7 Burner ignition at maximum and minimum limiting conditions
4.8 Delayed ignition at maximum and minimum limiting conditions
4.9 Burner reignition under draught conditions
4.10 Burner interference at ignition or during combustion
5 Performance tests
5.1 Flue operation
5.1.1 Design of appliance to divert combustion products away from wall
5.1.2 Mixing of combustion and incoming air
5.1.3 Flueing test gases
5.2 Thermal efficiency
5.2.1 Flue loss
5.3 Flue gas temperatures
5.3.1 Temperature at flue connection
5.4 Noise of operation
5.4.1 Excessive noise
5.5 Condensation
5.5.1 Control of flue gas condensate
5.5.2 Condensate—interference with combustion
5.5.3 Blocked condensate drain
5.6 Combustion air supply and controls
5.6.1 Proving means of mechanical air supply
5.6.2 Air supply failure
5.6.3 Pre-purge volume
5.6.4 Burner ignition
5.6.5 Burner reignition
5.7 Shutdown
5.7.1 Shutdown—appliance to be in a safe condition
5.7.2 Shutdown—limit device
5.7.3 Fault shutdown
5.8 Temperature hazards
5.8.1 Test conditions
5.8.2 Surrounding surfaces—temperature limits Floor, wall, overhead and bench surfaces
5.8.3 Personal safety—temperature limits Surfaces intended to be handled Surfaces accidentally touched
5.8.4 Appliance safety—temperature limits Bodies of gas valves, thermostats, etc Components containing non-metallic diaphragms Body of clock or timer Main gas and pilot lines susceptible to sulphide attack Electric motor windings Flexible hoses Joints sealed with jointing materials Electrical wiring Glass components
5.9 Heat resistance
5.9.1 Heat resistance—overload condition
5.9.2 Heat resistance—lit back condition
5.10 Explosion resistance
5.11 Strength and stability
5.11.1 Strength of flue connection
5.12 Noise of extinction
5.13 Burner stability when changing settings
Appendix A
Appendix B
B1 M.O.T. 2.2.5 – 98 Zinc alloy test
B1.1 Scope
B1.2 Method
B1.3 Apparatus
B1.4 Procedure
B1.5 Result
B2 M.O.T. 2.7.3/2.11 – 90 Markings and labels
B2.1 Scope
B2.2 Method
B2.3 Apparatus
B2.4 Materials
B2.5 Procedure
B2.6 Result
B3 M.O.T. 3.3.1 – 2003 Gas leakage
B3.1 Scope
B3.2 Method
B3.3 Apparatus
B3.4 Materials
B3.5 Preparation of apparatus
B3.6 Procedure
B3.7 Result
B4 M.O.T. 3.4.1 – 93 Gas consumption
B4.1 Scope
B4.2 Method
B4.3 Apparatus
B4.4 Materials
B4.5 Preparation of apparatus
B4.6 Procedure
B4.7 Result
B5 M.O.T. – 85 Ignition aerated pilots
B5.1 Scope
B5.2 Method
B5.3 Apparatus
B5.4 Materials
B5.5 Preparation of apparatus
B5.6 Procedure
B5.7 Results
B6 M.O.T. – 85 Ignition of burner protected by a flame safeguard
B6.1 Scope
B6.2 Method
B6.3 Apparatus
B6.4 Materials
B6.5 Preparation of apparatus
B6.6 Procedure
B6.7 Result
B7 M.O.T. – 88 Operation of flame safeguard
B7.1 Scope
B7.2 Method
B7.3 Materials
B7.4 Apparatus
B7.5 Preparation of apparatus
B7.6 Procedure
B7.7 Result
B8 M.O.T. (iii)/ (iii) – 94 Start flame establishment period - delayed ignition tests
B8.1 Scope
B8.2 Method
B8.3 Apparatus
B8.4 Materials
B8.5 Preparation of apparatus
B8.6 Procedure
B8.7 Result
B9 M.O.T. 4.2 – 95 Determination of CO/CO2 ratio of combustion products - surface combustion burners
B9.1 Scope
B9.2 Method
B9.3 Apparatus
B9.4 Materials
B9.5 Preparation of apparatus
B9.6 Procedure
B9.7 Result
B10 M.O.T. 4.3 – 95 Determination of CO/CO2 ratio in flue products
B10.1 Scope
B10.2 Method
B10.3 Apparatus
B10.4 Materials
B10.5 Preparation of apparatus
B10.6 Procedure
B10.7 Result
B11 M.O.T. 4.4 – 95 Determination of CO/CO2 ratio in flue products —Permanent pilots
B11.1 Scope
B11.2 Method
B11.3 Apparatus
B11.4 Materials
B11.5 Preparation of apparatus
B11.6 Procedure
B11.7 Result
B12 M.O.T. 4.5 – 93 Determination of CO/CO2 ratio in flue products on downdraught
B12.1 Scope
B12.2 Method
B12.3 Apparatus
B12.4 Materials
B12.5 Preparation of apparatus
B12.6 Procedure
B12.7 Result
B13 M.O.T. 4.6 – 94 Flame abnormality
B13.1 Scope
B13.2 Method
B13.3 Apparatus
B13.4 Materials
B13.5 Preparation of apparatus
B13.6 Procedure
B13.7 Result
B14 M.O.T. 4.7 – 88 Ignition tests
B14.1 Scope
B14.2 Method
B14.3 Apparatus
B14.4 Materials
B14.5 Preparation of apparatus
B14.6 Procedure
B14.7 Result
B15 M.O.T. 4.8 – 2003 Delayed ignition tests
B15.1 Scope
B15.2 Method
B15.3 Apparatus
B15.4 Materials
B15.5 Preparation of apparatus
B15.6 Procedure
B15.7 Result
B16 M.O.T. 4.9 – 2003 Flame stability to draught
B16.1 Scope
B16.2 Method
B16.3 Apparatus
B16.4 Materials
B16.5 Preparation of apparatus
B16.6 Procedure
B16.7 Result
B17 M.O.T. 5.1.4 – 89 Determination of CO/CO2 ratio in flue products under conditions of progressive flue blockage
B17.1 Scope
B17.2 Method
B17.3 Apparatus
B17.4 Materials
B17.5 Preparation of apparatus
B17.6 Procedure
B17.7 Result
B18 M.O.T. 5.1.5 – 89 Flame abnormality on downdraught
B18.1 Scope
B18.2 Method
B18.3 Apparatus
B18.4 Materials
B18.5 Preparation of apparatus
B18.6 Procedure
B18.7 Results
B19 M.O.T. 5.1.6 - 85 Effect of back pressure on pilot
B19.1 Scope
B19.2 Method
B19.3 Apparatus
B19.4 Materials
B19.5 Preparation of apparatus
B19.6 Procedure
B19.7 Result
B20 M.O.T. 5.2.1 – 89 Thermal efficiency – heat content of flue gases
B20.1 Scope
B20.2 Method
B20.3 Apparatus
B20.4 Materials
B20.5 Preparation of apparatus
B20.6 Procedure
B20.7 Calculation
B20.8 Result
B21 M.O.T. 5.3.1 – 89 Flue gas temperature test
B21.1 Scope
B21.2 Apparatus
B21.3 Materials
B21.4 Preparation of apparatus
B21.5 Procedure
B22 M.O.T. 5.5.3 – 01 Blocked condensate drain
B22.1 Scope
B22.2 Method
B22.3 Apparatus
B22.4 Materials
B22.5 Preparation of apparatus
B22.6 Procedure
B22.7 Result
B23 M.O.T. 5.6.1/2 – 91 Flame abnormality on progressive air supply restriction
B23.1 Scope
B23.2 Method
B23.3 Apparatus
B23.4 Materials
B23.5 Preparation of apparatus
B23.6 Procedure
B23.7 Result
B24 M.O.T. 5.8 – 03 Temperature hazards
B24.1 Scope
B24.2 Method
B24.3 Apparatus
B24.4 Materials
B24.5 Preparation of apparatus
B24.6 Procedure
B24.7 Result
B25 M.O.T. – 93 Temperature hazards - electric motors
B25.1 Scope
B25.2 Method
B25.3 Apparatus
B25.4 Materials
B25.5 Preparation of apparatus
B25.6 Procedure
B25.7 Calculations
B25.8 Result
B26 M.O.T. 5.9.1 - 85 Heat resistance
B26.1 Scope
B26.2 Method
B26.3 Apparatus
B26.4 Materials
B26.5 Preparation of apparatus
B26.6 Procedure
B26.7 Result
B27 M.O.T. 5.9.2 – 85 Heat resistance – lit back condition
B27.1 Scope
B27.2 Method
B27.3 Apparatus
B27.4 Materials
B27.5 Preparation of apparatus
B27.6 Result
B28 M.O.T. 5.11.1 – 85 Strength – loading test
B28.1 Scope
B28.2 Method
B28.3 Apparatus
B28.4 Preparation of apparatus
B28.5 Procedure
B28.6 Procedure
B28.7 Procedure
B28.8 Result
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
Cited references in this standard
Gas appliance standards — Definitions and calculations
Water supply and gas systems — Metallic fittings and end connectors
Manually operated gas valves
Thermoelectric flame safe guards
Electronic flame safeguards and flame detectors
Content history
DR 04158
AG 403-1986