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TRANSCRIPT
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31 50 006
"Gas Fired Air Heaters ': . " .... .... .
INSTRUCTION MANUAL ~~;.~. ""
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Mark II & Mark III Models
100 • 150 • 200
300 • 400 • 500
600 • 800 • 1000
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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS FOR PAKAWAY GAS FIRED AIR HEATERS
Models covered are:
Single Phase Three Phase 100 VNG1 (standard) 100 VNG3 (optional) 150 VNG1 (standard) 150 VNG3 (optional) 200 VNG1 (standard) 200 VNG3 (optional) 300 VNG1 (standard) *300 VNG3 (optional) 400 VNG1 (optional) *400 VNG3 (standard) 500 VNG1 (optional) *500 VNG3 (standard) 600 VNG1 (optional) *600 VNG3 (standard)
800 VNG3 (standard) 1000 VNG3 (standard)
THESE AIR HEATERS ARE FOR USE WITH NATURAL GAS ONLY
THEY MUST BE INSTALLED BY A COMPETENT PERSON AS STATED IN THE GAS SAFETY REGULATIONS 1972
,; Pakaway, whose policy is one of continuous development and improvement, reserves the right to alter any -~ specification appearing in this manual without notification.
If in any doubt on the interpretation of any instructions in this manual, please contact the Pakaway Sales Office, address and telephone number as on back cover.
Appliances asterisked have been approved by British Gas for use on natural gas.
G.C. numbers:
300 VNG3 42 534 01 .. 400 VNG3 42 534 02 . 500 VNG3 42 534 03
, . . 600 VNG3 42 534 04 ~ .'. . '
.-~ \ : ~~ '.. :... , ~ :' ., ,f
CONTENTS
Index Description Page no.
Section One - General 1A Introduction ..... . . .. .......... . .... . .... .. .. .... ...... . ... . .. . ...... ... ..... .. .......... 5 1B General requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1C Warranty ........ .. . .. . .. ..................... ... .................... . ...... . . . ...... . .. 5 1D Location .................................. .. . .. . . ...................... . ............... 6 1E Gas supply ........ .. . . . . . . .............. . .. . . .. ... . ...... , . . . . . . .. . . . . . . . . . . . . . .. . .. . . . 6 1F Boosted supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1G Flue system ....... . ...... . ................... . ................... . .. . .. . ............... 6 1H Air supply ............ . ......... . .......... . .................... . . ... .......... . ........ 7 1J Electrical supply . . . .. .... . .. . . . .. . .. .. ...... ... ... . . .. ... . .. . . . ... .. .... . .. . .. . ........ 7
Section Two - Installation of Air Heater 2A Heater unpacking . .. . . ....... " . .... ... ... . ... . . . . . . .. . .. . . . . . . . .. . . . . . . . . . . . ... ... . . . . 9 2B Installation clearances. . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . .. ... . .. .. .. . . . . 9 2C Connection of heater to flue system. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2D Gas connection .. ..................................................... .. ............... 9 2E Electrical connections . . . . . . . .. ...... .. ..... . .. . . . . . . ... ... . . .. .. . . . . . . . . . . ... .. .... . . . . 10 2F Electrical supply requirements ................... . ................ . , . . . . . . ... ...... . .. . 10
Section Three - Commissioning and Testing 3A Prel iminary precaut ions ..... . ... . ..... . . .. ..... . .................... .. ................ . 11 3B Control chassis check . .. ... . ......... . ......... . .. . .... . ........ . . .. . ... .............. . 11 3C Time switch chec.k .. ... .... . ............... . .... . . . . . ... . ........ ... . .. . .. .... . ... . ... . 11 3D Room thermostat check .. . ............... .. . . ............... . ... . .. . . . ....... . ........ . 11 3E Frost thermostat ... . .................... . . . . ... ............... . .... . . .. ............... . 11 3F Fan limit thermostat check ......................................... .. ................. . 11 3G Exp ~osion relief door check ............... .... . .. ..................................... . 11 3 H Fan check ......... .. ................... . ... .. ........................ . ................ . 11 31 Flue pipe arrangement ...................... . .................... . .... . ............... . 12 3J Air supply check . ... .. ..................... . ......... . .............. . ................. . 12 3K Gas supply check . . . ... . .................. .... . . ................. . ..... . ........ . ..... . 12 3L Burner check up . . . ... .... . .............. . . . ........ . ............ .. .. . ................ . 12 3M Gas soundness testing of the gas line - Heater models 100 & 150 . . . ... .. ........ .. . . . 13 3N Gas soundness testing of the gas line - Heater models 200 & 300 VNG ... ..... . .... . . 14 30 Gas soundness testing of the gas line - Heater models 400 & 500 VNG3 ... . ......... . 15 3P Gas soundness testing of the gas line - Heater models 600, 800 & 1000 VNG3 ....... . 16 30 Gas soundness testing and setting of monobloc gas train ............................. . 17 3R Lighting the air heater . ...................... . ...................... . ................. . 18 3S Main burner gas pressure adjustment ... . ........................... . . . ............... . 18 3T Combustion check . .. . .............................................. ... ............... . 18 3U Air pressure switch setting ................ .. ....................... . .. . ............... . 18 3V Flame failure lock-out check .............. ... .................... . . .. ................. . 19 3W General .............................. . .. .. .. ... ..................... . ................. . 19 3X Users instructlions - Advice to user . .. . .. . . ... ........... . .... .. .... .. .... . ........ .. .. . 19
Section Four - Servicing Servicing of air heater . . . . . . ... . . .. .. . . .......... . .. ........ ..... ..... ... . ... . ... .. .. . . . 21
Section Five - Fault Finding Faults and remedies ............................................. . .. . .................. 23
Section Seven - Technical Data 7A Data sheets ...... . . . ....................... . ...................... ... ................. . 25 7C Electrode settings . .. .. ... ............... . . .. . . ..................... .. ...... . .......... . 26 7D Ionisation current ... . .. .. . . . ...... . ...... . . . . . .. . .. . ............ . . ... .... .. . . ...... . . . . 26 7E Combustion head adjustment - Gas 2 burner . . .. ... . . . ... . .... .. .. . ........... . . ... .. . 27 7F Air pressure switch adjustment ........ . ... ... ... . ........... . ...... .. ............ . ... . . 27 7G Mounting' - Gas 3 burner ............ . . . .. . .. . .......... . ............ . . . ..... . ........ . . 27 7H Combustion head adjustment - Gas 3 burner ......................................... . 28 7J Ti·me switch setting . .................................................................. . 28
Section Eight - Wiring Diagrams & Commissioning Report Three phase air heater wiring diagram ........................... . .. . .................. 31 Single phase air heater wiring diagram..... . . . . . . . .. .. .. . . . .. ..... . . . . .. .. . ... .. . .. . . . . 31 Commissioning check list ................. . ........................ .. .................. 34
I , ~ ' .
Section One - General
1A INTRODUCTION
These instructions are intended to provide a guide to the procedure for a systematic check of the msta'tiation arrangements and of po~sible faults in the air heater arising during handling and 'installation.
The Pakaway heaters are gas fired fanned circulation air heaters which have output ratings as shown in the data sheet on page 25 and su~table for free-blowing and ducted applications.
The Pakaway heaters are to be floor-mounted and are primarily intended for heating and commercial or industrial premises.
The fan, located on the base of the heater, is of doub ~e inlet centrifugal type.
The fully automatic forced draught burner is located on the front face of the heater and is complete with pre-wired gas controls.
1B GENERAL REQUIREMENTS
Related Documents - Safety Note
The installation of the air heater(s) must be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations and the I.E.E. Regulations.
It should be in accordance also with any relevant requirements of the L.ocal Gas Region, Local Authority and Fire Authority and t'he relevant recommendations of the British Standards Codes of Practice.
CP.331 Part 3:- Installation of pipes and Meters for Natulral Gas. CP.3 Chapter IV:- Precautions against fire. British Gas Publication No. IM/11:- Flues for Commerciall and Industrial Gas Fired Boilers and Air Heaters. British Gas Publication:- Combustion and Ventilation Air. 1WAH MA Publication No. 2:- Standards of Installation for Gas Fired Industrial Warm Air Heaters.
The above related documents are, from time to time, revised and additional documents published. Whilst every effort is made to keep literature current, Pakaway cannot be responsible for this listing being correct or complete at the time of issue.
1C WARRANTY
Please refer to the 'Conditions of Sale' printed on the reverse side of the Sales Acknowledgement, copies of which can be supplied separately if requested from the Pakaway Sales Office.
Pakaway cabinet heaters are supplied backed by an extensive guarantee. The heater unit carries a twenty-four month guarantee on all parts commencing from the wor'ks despatch date. In addition, the combustion chamber/heater exchanger carries a ten year Time Related warranty.
The warranty is void if:(a) (i) The warranty registration/commissioning card has not been completed and returned to us within
fourteen days from delivery to site; (ii) The first service registration card is not completed and returned to us within twelve montlhs from
the date that the registration/commissioning card was returned. (b) Installation is not in accordance with the Codes and Standards listed in Section 1B General
Requi,rements of this manual. (c) The flue arrangement and air supply for the heater is not in accordance with the recommendation or
codes of practice referred to in this manual. (d) Air through heater is not provided in accordance with the technical specifications. (e) Internal wiring on heater has been modified without Pakaway permission and/or written agreement. (f) The main electrical supply input to the air heater has been switched on and off by other methods to
control heater, e.g. switched on and off via isolator. (g) Heater has been affected by the ingress of water. (h) The heater is not operated at the rating laid down in the technical data.
If a Claim Under Warranty is made then the following information is required to enable a replacement to be supplied: (i) Heater model (ii) Heater serial number (iii) Heater code number.
(This information, i.e. (i), (ii) and (iii) above, can be found on the data plate affixed to the front lower service access panel of heater.)
(iv) Original order reference (where known) or approximate date of supply and full site address and installer's name and address.
(v) Information and symptoms regarding the alleged fault
Faulty parts must be returned to Pakaway Sales Office for inspection to verify the claim.
Note: Notification is required immediately a fault is suspected, otherwise no responsibility can be taken for further damage, or expense incurred if other means are used to carry out rectification works.
5
10 LOCATION
The location chosen for the air heaters must permit the provision of a satisfactory flue system and an adequate air supply. The location must also provide adequate space for servicing and air circulation around the air heater.
The air heaters must be installed str~ctly in accordance with any fire regulations or insurance company's requirements appertaining to the area in which the heater is located, particularly where special fire risks are involved such as areas where petrol vehicles are housed, where cel'lulose spraying is carried out, in woodworking departments, etc.
The air heaters must be installed on a level non-combustible surface which is capable of adequately supporting the weight of the air heaters and any ancillary equipment. The heaters must be stable or rigidly fixed in order to prevent hazard to personnel.
The air heaters must not be installed in conditions for which it is not specifically designed, e.g. where the atmosphere is highly corrosive or salty and where high wind speeds may affect burner operation.
If the location of the air heater is such that it might suffer external mechanical damage, e.g. from overhead cranes, fork lift trucks, it should be suitably protected.
Any combustible material adjacent to the air heater and the flue system must be so placed or shielded as to ensure that its temperature does not exceed 65°C (150°F).
1 E GAS SUPPLY
Service pipes The local gas region should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the local gas region.
Meters A gas meter is connected to the service pipe by the local gas region or a local gas region contractor.
An existing meter should be checked, preferably by the gas region, to ensure that the meter is adequate to deal with the rate of gas supply required.
Installation pipes Installation pipes should be fitted in accordance with British Standards Code of Practice No. CP331:3.
Pipework from the meter to the air heater must be of adequate size. Do not use pipes of smaller size than the air heater gas connection.
The complete installation must be tested as described in the above code.
1 F BOOSTED SUPPLIES
Where it is necessary to employ a gas pressure booster the controls must include a jow pressure cut-off switch at the booster inlet.
The Ilocal gas region must be consulted before a gas pressure booster is fitted.
1 G FLUE SYSTEM
Refer to British Gas Publication No.1 M/11 - Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters.
The Pakaway heaters do not require a draught diverter, they are supplied with an integral flue-box allowing for the direct connection to an individual open-flue system.
Materials used for the flue system should be mechanically robust, resistant to internall and external corrosion, non-combustible and durable under t he conditions to which they are likely to be subjected.
Prevention of condensation within the flue shou lld be an important factor in the design o~ the flue system. In order to minimise condensation the use of double walled flue pipe or insulation is recommended. If double walled flue pipe is used it shou ld be of a type acceptable to BriHsh Gas.
Where condensation in the flue is unavoidable provision should be made for the condensate to flow freely to a point at which it can be released, preferably into a gully. The condensate pipe from the flue to the disposal point should be of non-corrodible material of not I'ess than 22mm (%in) size.
Facilities should be made for disconnecting the flue pipe from the air heater for inspection and servicing purposes. Bends with removable covers should be fitted for inspection and cleaning purposes where considered appropriate.
The flue system should ensure safe and efficient operation of the air heater to which it is attached, protect the combustion process from wind effects, and disperse the products of combustion to the external air.
The flue should terminate in a freely exposed position and must be situated so as to prevent the products of combustion entering an opening in a building in such concentration as to be prejudicial to health or a nuisance.
It i's recommended that a terminal be fitted at the flue outl'et.
6
1 H AIR SUPPLY
Refer to ~tish Gas Publication - Combustion and Ventilation Air.
In all cases there must be provision for an adequate supply of air for both combustion and general ventilation.
(a) Where heater is sited within area to be heated So far as any ventilation requirements are concerned, the installer should take note of any mandatory requirements for the provision of permanent air vents direct to outside. Any such air vents should have negligible resistance and must not be sited in any position where it is likely to become easily blocked or flooded nor in a position where it is possible for the ingress of toxic or flammable vapour. However, if the heater is sited within a building with an air infiltration rate of less than 0.5 per hour or where the build ing volume is less than 2.2 m3 per KW of heater input, then ventilation should be provided in accordance with the table of recommended minimum sizes.
(b) Where heater is si.ted within a plant room or conf,ined area Where the heater is sited within a plant room or other confined area, then provision must be made for the positive connection of either return air with high and low level ventilation in accordance with BS 6230 or if return air is through a louvre arrangement then the return air louvre must be of adequate size so as not to starve the main air distribution fan of air in addition to which the combustion air must enter through a duct which positively connects the burner combustion air fan to outside. Under no circumstances must the burner be left to operate within an area of negative pressure without a combustion air duct.
It is recommended that for applications such as (b) that you contact our Technical Department.
(c) Where the heater i's to operate within a toxic, corrosive or flammable atmosphere Under these circumstances, please consult our Technical Department.
The basic minimum effective area requirement of the air vent is as follows:
Gas heater model Air vent area per heater
100 180cm~ (28in~)I 150 270cm~ (42in~)
200 360cm~ (57 in A) 300 523cm A (80inA) 400 707cm A (107inA)A500 883cm (134in~) 600 1060cm A (160inA)A800 1450cm (219in
A
)
1000 1850cm A
(280in~)
1J ELECTRICAL SUPPLY
Wiring external to the air heater must be installed in accordance witlh I.E.E. Wiring Regulations and any local regulations which apply.
Models 100 to 300 are normally supplied for 240 volts, 50Hz, single phase, neutral and earth.
Models 400 to 1000 are normalily supplied for 415 volts, 50Hz, 3 phase, neutral and earth.
The method of connection to the mains electricity supply must facilitate complete electrical isolation of the air heater by an isolator having a contact separation of at least 3mm in all poles for three phase and 1.5m separation on single phase and the supply must serve only the air heater. The method of connection should be provided adjacent to the air heater in a readily accessible position.
For wiring instructions see page 31 .
7
GENERAL ARRANGEMENT OF CABINET & ACCESSORIES
Flue Pipe
~~~~~_-----------..,-- Air Nozzles
,b::!:::::::::==:::::====r~~~~~;;:=~:;;~------- Fan Limit Thermostat
Thermal Insulation Mark II
Ventilated Heat Shield on Mark II I
HHI----J--+H-l----- H eat Exchanger
1--~____--~f-__I--+tH---- Air Deflectors
---4,-Ht--+-- - Combustion Chamber
Burner
r?7iiK\--if::+------ Room Thermostat
~=-=:.-..-::-,++----- Ti me Clock
Control Chassis
Air Inlet Panel
Main Fan Drive Motor (Indirect Drive) Direct Drive Fans fitted on mode ls 100 to 300
Main Air Distribution Fan
8
Section Two - Installation of A,ir Heater
2A HEATER UNPACKING
The air heaters are despatched as follows: 1) Air heater complete with burner and flue box, all protected by plastic sheeting.
Note: Gas train may be disconnected from the burner and stowed in the heater fan compartment. 2) Air heater to~ plate dispatched separately. } N t I' ble t d ct head models. 3) Air nozzles dispatched separately. 0 app Ica 0 u
After heater is correctly positioned, locate heater top plate over spigot provided and then place air nozzles over outlets in top plate.
The air heater is to be floor-mounted on a level non-combustible surface which is capable of carrying the weight of the air heater and any ancillary equipment. See data sheet on page 25.
28 INSTALLATION CLEARANCES
The space in which the heater is to be fitted must have the following minimum dimensions:
Heater model Width Depth Height
100 & 150 1000mm (40in) 1525mm (60in) 2800mm (110in) 200 & 300 1000mm (40in) 2000mm (80in) 3000mm (120in) 400 & 500 1400mm (55in) 2200mm (87in) 3500mm (138in)
600 1400mm (55in) 2600mm (104in) 3650mm (144in) 800 1650mm (65in) 2450mm (98in) 3950mm (155in) 1000 1650mm (65in) 2550mm (102in) 3950mm (155in)
In addition to the dimensions mentioned above the following minimum clearances must be available at the front of the heater on heater models 800 and 1000, at the back of the heater also on heater models 100 to 600 to enable heater to be serviced.
Heater model Clearance 100 & 150 760mm (30in) 200 & 300 1000mm (40in) 400 & 500 1000mm (40in)
600 1000mm (40in) 800 1270mm (50in) 1000 1270mm (50i n)
2C CONNECTION OF HEATER TO FLUE SYSTEM
The heaters do not normally require a draught stabiliser, as they are supplied with an integra~ flue-box allowing for the direct connection to an individual open flue system.
The flue pipe disposes of the gases from the burner and its correct functioning is a most vital part of the heater.
Make sure the flue pipe is sealed into the socket on the heater and elsewhere using a suitable sealant material. If a draught stabiliser is fitted, check that it is in the closed pOSition. Check that it is free to move and not prevented from swinging by foreign objects or damaged in any way.
It Is imperative that where a flue passes through roof, this opening is properly sealed by roof plate and cravat to ensure no water e nters.
NO CLAIMS FOR ANY DAMAGE RESULTING FROM INGRESS OF WATER WILL BE CONSIDERED.
Flue pipes must not have sharp bends. Easy obtuse bends are necessary to assist the flow of gases. Flue terminal cowls as demanded by site conditions are necessary.
Care must be taken that the flue height and materials used, meet all the necessary requirements and codes. (Refer to General Requirements on page 5 of these instructions.)
20 GAS CONNECTION
Heater models 100, 150, 200, 300, 400 & 500 Fit burner gas train to burner at union connection on the underside of blast-tube, the gas train can be positioned for either left or right hand gas supply pipe connection.
Fit the two electric plugs on the flying leads from the gas train into the sockets located on the back face of the burner, these plugs are not interchangeable.
Heater model 600, 800, 1000 Fit burner gas train to burner at flange connection on the underside of blast-tube using gasket and fixings
·supplied. The gas train can be positioned for either left or right hand gas supply pipe connection.
Fit the three electric plugs on the flying leads from the gas train into the sockets located on the underside of the burner housing. (Note: The 3 pin plugs on the pilot gas valves can be safely interchanged.)
The gas pipework should be sized to produce the required gas volume so that at least the minimum inlet pressure (see page 25) is obtained to the burner manifold, to give the required head pressure.
9
The local gas region prefer to be consulted regarding each installation and they will advise as to the pressure of gas supply and the recommended pipe sizes for single or multi-heater installations.
Note: Each heater must be fitted with a gas supply isolating cock and a suitable union. (The cock to be upstream and adjacent to the union which in turn must be upstream of the burner outlet.)
These items can be supplied as an optional.
Under no circumstances must the gas pipework be used as an electrical earth.
2E ELECTRICAL CONNECTIONS
Note: All electrica'i wiring and connections must be made in accordance with the I.E.E. regulations. Check any local regulations that apply, Le. garage installations or hazardous environments.
Check rating plate on heater for supply voltage requirements. Connect supply from a suitably fused isolator or a local isolator on a suitably fused supply to the mains terminal strip in the wiring chassis of the air heater (see wiring diagram on page 31).
Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.
All external wiring must be enclosed within approved conduit. Conduit from isolator switch must run so as not to interfere with service panels of the air heater.
Whether a single heater or a number are to be wired as part of a single installation, an isolator must be provided, so that each heater can be separately d,isconnected. The isolator switch shouId be located in a readHy accessible position. Each heater should be independently fused.
Controls from one heater to another heater must not be interwired.
2F ELECTRICAL SUPPLY REQUIREMENT
Model 100 - 300 15 amp single phase (optional- 10 amp three phase) Model 400 - 600 15 amp three phase and neutral (optional- 30 amp single phase) Model 800 & 1000 30 amp three phase and neutral
Check voltage on nameplates agrees with electrical supply.
Time switch, roomstat and froststat These are supplied as an integral part of the air heater, refer to Commissioning Instructions.
I~ r, IIi Ii
Section Three - Commissioning and Testing
3A PRELIMINARY PRECAUTIONS
All heaters must be commissioned. test fired and serviced by a competent gas engineer. a) Before attempting any check; switch off electrical supply to heater at main isolating switch
and remove fuses.
b) Shut off main gas isolating cock to unit.
Note: The unit is·not isolated electrically until the main isolator is switched off and the fuses are removed. Switchi,ng off at the summer/winter switch ils not sufficient when work is being carried out on the unit.
3B CONTROL CHASSIS CHECK
Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.
Check that all wires on control chassis are secure, and tHat no strands of multi-strand cables are near, or bridging across terminals or to earth.
Check that reset buttons operate freely.
3C TIME SWITCH CHECK
Aqjust time switch for required ON/OFF sequence.
Refer to page 28 for setting instructions.
3D ROOM THERMOSTAT CHECK
The operation of the room thermostat can be checked as follows:
With the indicator set to the high limit of the scale and the burner firing, slowly reduce the scale setting, at actual room temperature, the burner should shut down. After the test the room thermostat should be set to the temperature required.
3E FROST THERMOSTAT
This is wired across switched circuit by-passing the time switch control and wil l not effect commissioning and testing whilst time switch is on ON cycle.
3F FAN LIMIT THERMOSTAT CHECK
Check and ensure that the combination fan I'imit thermostat settings are as specified below:
FAN OFF = 30°C (86°F) FAN ON = 60°C (140°F) LIMIT = 120°C (250°F)
Make sure the combination control is set to auto Le. white button pulled outwards. Some models also have a RED reset button. Push to reset If this red reset button requires operating during normal service of the heater, the cause should be determined and rectified as soon as possible to avoid possible damage to the heater.
These settings must not be increased, although the fan ON and fan OFF can be lowered if desired.
3G EXPLOSION RELIEF DOOR CHECK
Check that the door is free to open and that it is not obstructed in any way by piping etc.
3H FAN CHECK
Important: First isolate electrical supply and remove fuses.
Remove screws retaining air inlet panel and remove panel for access to fan.
Rotate fan by hand to check that it is running freely, and that it is free from foreign bodies in the fan blades.
Check pulley tightness on shafts.
Check fan belt tension which should give approximately 6mm (1/4in) belt movement up and down at mid001 t. Adjust by moving motor on slide rails.
Jck tightness of fan shaft bearing locking coHars.
Replace air inlet panel and retaining screws.
Replace fuses and switch on e.lectrical supply to unit.
Check rotation of fan. ,,
Move summer/winter switch to 'Summer' to run fan only. Fan should run in direction giving the most air volume from the unit. If it runs in the reverse direction, return switch to OFF, turn off electrical supply at
. main isolating switch and remove fuses. Then reverse any two of the incoming phases at the heater terminal block. Replace fuses. Turn on isolator. Check again for correct rotation. Return switch to OFF position.
Models 100/300 have single phase direct drive fan units. Check details as applicable.
31 FLUE PIPE ARRANGEMENT
Check that the flue pipe arrangement has been carried out in accordance with the design requirements. Refer to section on 'Connection of Heater to Flue System' on page 9 of this manual.
Check flue pipe joints at heater and elsewhere.
Check for flue obstruction.
3J AIR SUPPLY CHECK
The heater requires air for combustion and for heating the building.
It is important to check to ensure that the installation work has been carried out in accordance with the design requirements, paying particular attention to the air requirements stated in the section on Air Supply on page 7 in this manual.
If there is any doubt on this matter consult Pakaway, address and telephone number as on back cover of this manual.
3K GAS SUPPLY CHECK
Check that type of gas being used is correct for burner. Heaters are supplied with burners suitable for natural gas unless otherwise specified.
Check main burner isolating gas tap operates freely. Open and close by hand.
Check supporting arrangements of the pipeline to ensure that lines are correctly supported and that unions are not strained by excessive lengths of free pipe.
The whole of the gas installation including the meter, should be inspected and tested for soundness and purged in accordance with the recommendations of British Standard Code of Practice 331 :3.
3L BURNER CHECK UP
Turn OFF gas at main isolating tap and electrical supply at main isolating switch.
Reillo gas burner on heater models 100, 150, 200, 300, 400 & 500 Remove the burner cover by loosening the three retaining screws and then pull cover away from burner.
Remove the two electrical plugs (one plug on models 100/150) on the flying leads from the gas train from the sockets on the back face of burner.
Remove top of burner fan housing by undoing securing screw, this gives access to the leads to the electrode and flame probe.
Remove leads from the electrode and flame probe, tlhe burner can now be separated from the blast tube and firing head by loosening the nut and turning the latch at the top front of the blast tube.
Remove the socket head screw (1) on page 27 and remove firing head (2) from blast tube (Section 7E). Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked in the factory and should not require re-setting. Replace firing head (Section 7C).
Firing head setting Two separate adjustment settings have to be made; one for the air and one for the gas. Refer to table on page 25 for setting numbers.
Method for air-setting (Refer page 25, Section 7 E) Loosen the screw (1), move the firing head (2) so that its rear edge (3) is level with the desired setting number on the page (4). Then tighten the screw (1).
Method for gas setting (Refer page 25, Section 7E) Loosen the screw (5), move the ring (6), so that the pointer (7) is level with the desired setting number (8). Then tighten the screw (5).
Replace the burner to the blast tube and replace latch and tighten nut.
·Replace Ileads to electrode and flame probe and replace fan housing cover.
Replace the electric plugs on the flying leads from the gas train into the sockets located on the back face of the burner, these plugs are not interchangeab e.
Ensure that electrical connections to burner and controls are secure. , ?
Reillo gas 3 burner on heater model 600, 800 & 1000 Remove the three electric plugs on the flying leads from the gas train from the sockets on the underside of the burner housing.
Separate the firing head from the rest of the burner by removing the two screws (1) on page 27 and withdrawing the burner body on the holding-bars (2) (Section 7G).
The action of puHing the burner-body from the firing head will release the leads from the electrode and flame probe.
Remove the two socket head screws (1) on page 28 and remove firing head (2) from blast tube (Section 7H).
Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked in the factory and should not require re-setting (Section 7C).
Replace firing head.
Firing head setting Two separate adjustments have to be made; one for the air and one for the gas. Refer to table on page 25 for setting numbers.
Method for air setting (Refer page 28, Section 7H) Loosen the two screws (1) and move the firing head (2) so that it's rear edge (3) is level with the desired setting number on the plate (4).
Then tighten the screws (1).
Method of gas setting (Refer page 28, Section 7H) Loosen the screws (5), move the ring (6) so that the pointer (7) is Ilevel with the desired setting number (8). Then tighten the screws (5).
Replace the burner-body to the blast tube making sure the leads to the electrode and flame probe are reconnected, the use of pliers will help in connecting the two leads. Replace the two securing screws.
Replace the electric plugs on the flying leads from the gas train into the sockets located on the underside of the burner housing. (Note: the 3 pin plugs on the pilot gas valves can be safely interchanged.)
Ensure that electrical connections to burner and controls are secure.
EstabHsh type of gas train fitted, that is conventional or CG Monobloc. Use appropriate testing scheme.
3M GAS SOUNDNESS TESTING OF THE GAS TRAIN - HEATER MODELS 100 & 150
T cr::::::>>+-I--~c:>tJ · :f c:G1------~f-------.-A, B Manual shut off valves 1 Main governor 2 Safety shut off valve 3 Operating valve
1. Switch off the heater. Isolate the electrical supply and close manual gas valves A & B.
Testing the pipework up to the upstream safety shut off valve 2. Connect a water column pressure gauge to pressure test point P1.
3. Open valve A to pressure the assembly up to the seat of the safety shut off valve.
4. Close valve A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If pressure falls, open valve A and test for leaks with soap solution. Make good as necessary and recheck. Note: Two minutes should be allowed for all soap solution tests.
Testing upstream safety shut off valve 5. Close valve B and open valve A Connect the pressure gauge to test point P2. If a rise in pressure is
observed then the safety shut off valve seat is paSSing. Make good and recheck.
Testing downstream operating valve . 6. link pressure test points P1 and P2 with rubber tube and a tee piece. Connect the pressure gauge to
the tee piece. Open valve A and valve B. Then close valve A If a drop is observed then either the downstream operating valve is passing or the pipework between the safety shut off valve and the operating valve is leaking.
7. Close valve B, open valve A and test the enclosed pipework for leaks with soap solution. Make good and retest.
8. If the pipework is not leaking then the operating valve seat is paSSing. Make good and retest.
13
3N GAS SOUNDNESS TESTING OF THE GAS TRAIN - H'EATER MODELS 200 & 300
A
A, B& C Manual sh ut off valves 1 Main governor 2 Upstream safety shut off valve 3 Downstream safety shut off valve 4 Pilot safety shut off valve 5 Pressure test points
Procedure 1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off valve 2. Connect a water column pressure gauge to pressure point P1.
3. Open valve A to pressurise the governor assembly.
4. Close A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls. open A and test for leaks with soap solution. Make good as necessary and recheck.
Note: Two minutes should be allowed for all soap solution tests.
5. If no external leaks are observed, the upstream safety shut off valve is passing.
To check this remove the screw from pressure test point P3 and depressurise the space between the safety shut off valves.
Connect the water column pressure gauge and leave for 2 minutes with A still open. A rise in pressure confirms the first valve is passing. Make good and recheck for soundness.
Testing the downstream safety shut off valve & pilot safety shut off valve 6. Close valve A and connect pressure test points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the assembly up to the seats of the downstream safety shut off valve and pilot safety shut off valve.
8. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure faUs, open A and test the pipework connecting the safety shut off valve for leaks with soap solution. Make good as necessary and recheck.
9. If no external leaks are observed either the downstream safety shut off valve or the pilot safety shut off valve is passing. To check this remove the screw from pressure test point P4 and depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P4 and leave for 2 minutes with A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good and recheck for soundness. Then remove the pressure gauge from test point P4 and connect to test point P6 and leave for 2 minutes with A still open. A rise in pressure confirms the pilot safety shut off valve is passing. Make good and recheck for soundness.
Testing the downstream pipework 10. Close valve A and connect pressure test points P2 and P4 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open A and test for leaks in the pipework downstream of the safety shut off valves with soap solution. Make good as necessary and recheck.
Testing the downstream pilot line pipework 13. Close valve A and connect pressure paints P2 and P6 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
14. Open valve A to pressurise the line to valve C.
15. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open A and test for leaks in the pipework downstream of the pilot safety shut off valve with soap solution. Make good as necessary and recheck.
30 GAS SOUNDNESS TESTING OF THE GAS LINE HEATER MODELS 400 & 500 VNG3
A P5
A,B&C Manual shut off valves 1 Main governor 2 Upstream safety shut off valve 3 Downstream safety shut off valve 4 Pilot safety shut off valve 5 Pressure test paints
Procedure 1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off and pilot safety shut off valves 2. Connect a water column pressure gauge to test point P1.
3. Open valve A to pressurise the assembly up to the seats of the upstream safety shut off and pilot safety shut off valves.
4. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure faUs, open A and test for leaks with soap solution. Make good as necessary and recheck. Note: Two minutes should be allowed for all soap solution tests.
5. If no external leaks are observed either the upstream safety shut off valve or the pilot safety shut off valve is paSSing. To check this remove the screw from pressure test point P3 and depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P3 and leave for 2 minutes with A still open. A rise in pressure confirms the upstream safety shut off valve is paSSing. Make good and recheck for soundness. Then remove the pressure gauge from test point P3 and connect to test point P6 and leave for two minutes with A still open. A rise in pressure confirms the pilot safety shut off valve is paSSing. Make good and recheck for soundness.
Testing downstream safety shut off valve 6. Close valve A and connect pressure points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the line up to the seat of the downstream safety shut off valve.
8. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open A and test for leaks in the pipework between the safety shut off valves with soap solution Make good as necessary and recheck.
9. If no external leaks are observed, the downstream safety shut off valve is passing. To check this remove the screw from pressure test paint P4 and depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect it to test point P4 and leave for 2 minutes with valve A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good and recheck for soundness.
Testing the downstream main-line pipework 10. Close valve A and connect pressure test points P2 and P4 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open A and test for leaks in the pipework downstream of the safety shut off valves with soap solution. Make good as necessary and recheck.
Testing the downstream pilot line plpework 13. Close valve A and connect pressure test points P2 and P6 with a length of rubber tubing. Connect the
pressure gauge to test paint P1.
14. Open valve A to pressurise the line to valve C.
15. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open A and test for leaks in the pipework downstream of the safety shot off valves with soap solution. Make good as necessary and recheck.
3P GAS SOUNDNESS TESTING OF THE GAS HEATER MODELS 600, 800 & 1000 VNG3
A B P1 P5
3 4
A,B&C Manual shut off valves 1 Multifunctional gas control incorporating the main governor and up and downstream
shut off valves 2 Pilot line governor 3 Upstream pilot safety shut off valve 4 Downstream pilot safety shut off valve 5 Pressure test points
Procedure 1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off and pilot shut off valves 2. Connect a water column pressure gauge to pressure test point P1.
3. Open valve A to pressurise the assembly up to the seats of the upstream safety shut off and upstream pilot safety shut off valves.
4. Close valve A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open valve A and test for leaks with soap solution. Make good as necessary and recheck. Note: Two minutes should be allowed for aU soap solution tests.
5. If no external leaks are observed either the upstream safety shut off valve or the upstream pilot safety shut off valve is passing. To check this remove the screw from pressure test point P3 and depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P3 and leave for 2 minutes with valve A stil l open. A rise in pressure confirms the upstream safety shut off valve is passing. Make good and recheck for soundness. Then remove the pressure gauge from test point P3 and connect to test pOint P7 and leave for 2 minutes with valve A still open. A rise in pressure confirms the upstream pilot safety shut off valve is passing. Make good and recheck for soundness.
Testing downstream safety shut off valve 6. Close valve A and connect pressure test points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the line up to the seat of the downstream safety shut off valve.
8. Close valve A Leave system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open valve A and test for leaks in the pipework between the safety shut off valves with soap solution. Make good as necessary and recheck.
9. If no external leaks are observed, the downstream safety shut off valve is passing. To check this remove the screw from pressure test point P4 and depressurise the downstream pipework. Remove pressure gauge from test point P1 and connect to test point P4 and leave for 2 minutes with valve A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good and recheck for soundness.
Testing the downstream plpework 10. Close valve A and connect pressure test pOints P2 and P4 with a I,ength of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close valve A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open valve A and test for leaks in the pipework downstream of the safety shut off valves with soap solution. Make good and recheck.
Testing downstream pilot safety shut off val,ve 13. Close valve A and connect ,pressure test points P2 and P7 with a length of rubber tubing". Connect the
pressure gauge to test point P1.
14. Open valve A to pressurise the pipework up to the seat of the downstream pilot safety shut off valve.
15. Close~lve A Leave the system for 2 minutes and watch for a falj in pipework pressure. If the pressure falls, open valve A and test for leaks in the pipework between the safety shut off valves with soap solution. Make good as necessary and recheck.
16. If no external leaks are observed, the downstream pilot safety shut off valve is passing. Tb check this remove the screw from pressure test point P1 and depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect to test point IP8 and leave for 2 minutes with valve A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good and recheck for soundnes&
Testing the downstream pilot line pipework 17. Close valve A and connect pressure points P2 and P8 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
18. Open valve A to pressurise the line to valve C.
19. Close valve A Leave system for 2 minutes and watch for a fall in pipework pressure. If the pressure falls, open valve A and test for leaks in the pipework downstream of the safety shut off valves with soap solution. Make good as necessary and recheck.
30 GAS SOUNDNESS TESTING & SETTING OF MONOBLOC GAS TRAIN
A P1 P2 P3 B
--,..~--~~---~~===c:I==r1~__~~-r=~~~.~_ A, B Manual shut off valves P1, P2, P3 - Pressure test pOints C Main block
Procedure 1. Switch off the heater. Isolate the electric supply and close manual gas valves A & B.
Testing the upstream pipework to the block 2. Connect a water column pressure gauge to P1.
3. Open A to pressurize to block.
4. Close A. Leave for 2 minutes. If pressure falls test for leaks with soap solution between A and block. Make good as necessary and recheck.
Note: Two minutes should be aillowed for all soap solution tests.
Testing the first stage valve 5. Connect water column pressure gauge to P2 and open A If a pressure rise is observed the first stage
valve seat is passing. Rectify or replace and recheck.
Testing the downstream pipework for the block 6. Close A. link P1 and P3 with rubber tube and via a T piece connect a water column pressure gauge.
Open A to pressurize the system. Close A and leave for two mi,nutes. If a fall in pressure is observed, test for leaks between the block and B. Make good as necessary and recheck.
Testing the second stage valve 7. Link P1 and P2 with rubber tube. Connect water column pressure gauge to P3. Open A If a pressure
rise is observed then the second stage is passing. Rectify or replace and recheck.
I ~I
ST HOLD SCREW •
PS PG
17
Use 2.5mm Allen Key to adjust - DO NOT FORCE.
PS - Adjust the start gas pressure PG - Adjust the main gas pressure ST - When released 1-2 turns holds the control on start gas rate
Initial start of burner and adjustment 1. Release screw ST 1-2 turns.
2. Set control PS to a low value on scale and ensure control PG is set to a low value but slightly greater value than that of control PS.
3. Start burner and set control PS to give an increase in pressure of 0.5" wg. (1.25 mbar) at the burner head over the proving air value.
4. Close screw ST.
5. Set control PG to give specified burner head pressure.
The transfer from start to main gas is automatic and occurs 5-7 seconds after PS is energised or 5-7 seconds after screw ST is closed.
3R LIGHTING THE AIR HEATER
When all the commissioning checks have been completed the following procedure should be adopted for lighting the burner and carrying out combustion checks.
i) Open all gas valves. ii) Set the time switch to an 'ON' cycle. iii) Ensure that the thermostat(s) are calling for heat iv) Set summer/winter switch to 'Winter' position. v) Switch on the mains electricity supply to heater. The heater should now start.
The normal burner start-up cycfe is as follows:
Thermostats etc. Motor Ignition transformer Start gas valves Start gas flame Main gas valve Main flame
If main flame cannot be established, then contact Pakaway.
Do not attempt to open the burner control box as once the seals are broken the guarantee is void.
After a flame has been established check for gas soundness around the air heater gas components using a leak detection fluid.
3S MAIN BURNER GAS PRESSURE ADJUSTMENT
After the burner has been firing for at least 10 minutes check the gas pressure at the burner head is as listed -in data sheet on page 25. Adjust the pressure if necessary at the gas governor in the gas train line or on the monobloc if fitted.
The main burner pressure test point is located at the side of gas inlet to the burner head.
3T COMBUSTION CHECK
When the correct gas pressure has been established, adjust the combustion air shutter at the burner to give carbon dioxide (C02) reading at the flue outlet of 8.5 to 9.0%.
Secure the air shutter.
The flame can be viewed from the viewing port on the burner or from the explosion relief door on the back face of the heater on models 100 to 600 and on front face of heater on 800 and 1000 models. Care should be taken when doing this as it is a pressurized combustion chamber.
IdeaUy the burner flame should be close to the burner head, pale blue in colour and have sl'ightly whitish yellow tips to the flame end. The flame must not impinge on the end or side of the combustion chamber.
3U AIR PRESSURE SWITCH SETTING
Adjust the setting of the air pressure switch after all other adjustments have taken place, starting from the sett ing at the bottom of the scale.
While the burner is firing, increase the pressure by slowly turning the regulating knob clockwise until gas valve closes.
Then turn the knob back by two turns and restart the burner, thereby checking that it functlions correctly, should the burner again go to lockout, turn the knob back by one more full turn.
3V FLAME FAILURE LOCK-OUT CHECt'
I'f flame fai lure occurs when the burner is firing lock-out should take place within one second.
To check this turn off the main gas supply isolat ing valve whilst the burner is firing and the neon light in the burner control, box reset button should come on immediately.
To restart burner, open gas isolating valve and press burner control box reset button, the burner will then go through the normal start-up cycle.
3W GENERAL
When all checks are complete replace the burner cover and tighten the three retaining screws. Finally recheck the combustion to make sure that the fitting of the burner cover has not altered any conditions.
Re-adjust all controls to suit customers requirements.
Note: During all tests when the burner is firing the main heater fan operates independently under control of the fan thermostat.
3X USER INSTRUCTIONS - ADVICE TO USEIR
Upon satisfactory completion of commissioning and testing hand the User's Instructions to the user or purchaser and explain the method of economic and efficient operating of the system.
Ensure that the user or purchaser is fully conversant with the lighting, shut down and general operational procedure.
Advise the user or purchaser that for continued efficient and safe operation of the air heater, it is important that adequate servicing is carried out at regular intervals.
Replace the burner-body to the blast tube making sure the leads to the electrode and flame probe are reconnected, the use of pliers will help in connecting tlhe two leads. Replace the securing screws.
Replace the electric plugs on the f,lying leads from the gas train into the sockets located on the underside of the burner housing. (Note: The 3 pin plugs on the pilot gas valves can be safely interchanged.)
Remove the top burner cover to give access to burner controls and wiring and check all the electrical connections are secure.
Replace top burner cover.
4. Testing When servicing is completed, replace the fuses and switch on main electric supply.
Check gas soundness of the gas line as described on pages 13 to 16.
Light the heater and carry out all the tests as described in the Commissioning and Testing Instructions.
Quote heater model, serial number and code number when ordering spare parts.
Section Four - Servicing of Air Heater
The air heater is constructed to give long trouble free service, but in common with all mechanical apparatus, it needs periodic attention.
The following routine of maintenance checks should be carried out annually, preferably before commencement of the heating season.
Before commencing maintenance, isolate heater as follows:
Set summer/winter switch to 'OFF' position. Turn off main gas isolating valve. Switch off main electric supply isolator and remove fuses.
1. Clean flue box and heat exchanger unit Remove the access covers on the flue box and brush the flue ways, flue box and flue system.
Remove all loose carbon material before replacing the access covers.
2. Clean main fan and housing and check fan belt tensions Remove front and back air inlet pane,ls for access to fan housing.
Clean main fan of dust, paper etc. and check bearings for wear.
Check tightness of belts, pulleys on fan and motor shafts, tighten set screws if necessary.
Check fan belt tension which should give approximately 6mm (1f4in) belt movement up and down at midpoint. Adjust by moving motor on slide rails.
If all adjustment is taken up replace belt(s).
Note: Some units are fitted with direct drive main fans - if so, omit only the above references to belts and pulleys.
Replace back air inlet panel.
Before replacing front air inlet panel examine the electrics for loose connections and check reset button(s) operate freely.
Replace front air inlet panel.
3. Burner servicing
Riello Gas burner on heater modells 100, 150, 200, 300, 400 & 500 Remove the electric plugs on the Hying leads from the gas train, from the sockets on the back face of the burner.
After removing the burner cover, remove top of burner fan housing by undoing securing screw. This gives access to the electrode and flame probe leads.
Remove these leads and the burner can now be separated from the blast tube by loosening the nut and turning the latch at the top front of the blast tube.
Remove the socket head screw and remove firing head from the blast tube. Brush clean if necessary.
Check that the ignition electrode and flame probe are pOSitioned as shown on page 26, also clean electrodes and check porcelains for hairlline cracks, dust and carbon.
Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the Commissioning and Testing Instructions.
Replace the burner to the blast tube and replace latch and tighten nut.
Before replacing leads to electrode and flame probe make sure the burner fan ,housing and all burner components are clean and free of dust.
Re-connect the plugs on the flying leads from the gas train into the sockets on the burner.
Examine all the electrical connections to burner and controls.
Riello Gas 3 burner on heater model 600, 800, 1000 Remove the three electric plugs on the flying leads from the gas train, from the sockets on the underside of the burner housing.
Separate the firing ,head from the rest of the burner by removing the securing screws and withdrawing the burner-body on the holding bars.
The action of pulling the burner-body from the firing head will release the leads from the electrode and flame probe.
Remove the two socket-~ead screws and remove firing head from the blast tube.
Check that the ignition electrode and flame probe are positioned as shown in page 26. Also clean electrode and check porcelains for hairline cracks, dust and carbon.
Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the CommisSioning and Testing Instructions.
21
Section Five - Fault Finding
FAULTS AND REMEDIES
Before making any adjustments ensure that the burner is electrically isolated.
Burner fails to start 1. One of the controls in the circuit not making contact such as the time switch, room thermostat, limit
thermostat or the air pressure switch. 2. Burner control box locked-out. 3. Check electrical supply.
Burner starts, fails to light and locks-out 1. Check gas supply, gas va lves and pressure settings. Re-purge if necessary. 2. No spark at electrode. Check electrode setting. 3. Spark does not ignite gas. Check electrode setting. 4. Check for flue blockage.
Burner motor starts, but not the control box sequence 11. The air pressure switch does not close its contacts. Check setting of air pressure switch. Replace if
defective.
Burner ignites and then locks-out 1. Flame probe incorrectly set. Check setting. 2. Excessive combustion air causing flame to lift off burner head. 3. Insufficient gas. Check gas supply. 4. Gas pressure too high. Check gas rate and pressure. 5. Check air pressure switch. 6. Check earth connections are secure and wired correctly to a good earthing source.
Burner locks-out during pre-purge or after shutdown 1. Flame sensed, check gas valves. 2. Check control box, replace if defective.
Burner pu,lsates when running 1'. Overiiring. Check gas rate. 2. Incorrect mixture. Adjust burner.
Insufficient air supply from main fan 1. Loose or worn fan belt(s), pulleys insecure. 2. Incorrect fan rotation (three phase). See page 11, Section 3H - Fan Check. 3. Air inlets obstructed. 4. Fan blades choked. 5. Excessive external air resistance.
Noisy main fan 1. Loose or worn fan belt(s). 2. Loose or worn bearing locking caps. 3. Worn bearings. 4. Pulleys insecure. 5. Paper etc. in fan causing imbalance. 6. Worn or dry motor bearings. 7. Loose fan support.
Fan starts when isolating switch is turned on but summer/winter is in OFF position 1. Make sure the fan limit combination is set to auto, i.e. white button pulled outwards.
22
Section Seven - Technical Data
7A DATA SHEET MK II Sept. 1987
HEATER MODEL 100 150 200 300 400 500 600 800 1000
I RIELLO BURNER TYPE GAS H GAS I GAS I GAS 2 GAS 2 GAS 2 GAS 3 GAS 3 GAS 3
BURNER GAS SETTING PRESSURE
mbar 3.68 4.9 6.1 4.9 6.1 7.2 6.8 6.86 8.09
ins.wg. 1.5 I 2.0 2.5 2.0 2.45 2.9 2.73 2.8 3.3
BURNER AIR SETTING
N/A 2 2.75 1 3 5 1 3 3
1 BURNER GAS SETTING 2 2 2.75 0 3 4 0 7 7
HEAT INPUT
kW 40.4 54.65 75.72 116.2 150.3 188.4 226.5 311 .5 390.4
Btu/h 137.862 186.300 253.368 ,
396.500 512.820 642.800 772.700 1.061 ,910 1,331 .010
HEAT OUTPUT
kW 30.6 44.0 56.2 87.9 117.21 146.5 175.8 234.0 293.0
Btu/h 112,000 150.000 202,060 300,000 400,000 500,000 600.000 800,000 1,000,000
BURNER GAS INLET CONNECTION
'12 " EXT
'12 " EXT
'12" EXT
34" BSP EXT
1" BSP EXT
1" BSP EXT
1" BSP INT
1" BSP INT
1V2" BSP INT
FLUE SIZE
mm 152 152 200 200 200 200 250 250 250
ins. 6 6 8 8 8 8 10 10 10
MIN INLET PRESSURE TO OBTAIN HEAT INPUT
mbar
ins.wg.
12.5
5.1
10.29
, 4.2
13.48
5.5
14.0
5.8
113.0 14.2 13.5 14.0 14.46
1
5 . 2 5.7 5.42 5.8 5.9
MAX INLET PRESSURE
mbar 20 20 20 20 I 20 20 20 20 20 . ins.wg. 8 8 8 8 8 8 8 8 8
DATA SHEET MK III GAS SERIES BURNERS
HEATER MODEL 100 150 200
BURNER GH G 1 G 1
HEAD mbar 3.7 4.9 6.1
PRESSURE ins.wg. 1.5 2.0 2.5
BURNER AIR SHUTTER N/A 2.0 2.8
BURNER GAS HEAD 2.0 2.0 1
2.8
HEATER kW 40 . 55 76
INPUT Btux 103 138 186 253
HEATER kW 31 44 56
OUTPUT Btux 103 112 150 202
GAS INLET '12 " V2' 3/4 " CONNECTION I
FLUE SIZE mm 125 125 150
(NOMINAL) ins. 5 5 6
I mbar 12.5 10.3 13.5MIN. GAS I INLET PRESS. ins.wg. 5.1 4.2 5.5
MAX. GAS I mbar 20 20 20
INLET PRESS. ins.wg. 8 8 8
Kg 208 208 407 WEIGHT
Ibs 458 458 1
897
300
G2
4.9
2.0
1.0
0.0
116
397
88
300
3/4'
150
6
14.0
5.8
20
8
407
897
400 500 600 800 1000
G2 G2 G3 G3 G3
6.1 7.2 6.8 6.9 ! 8.0
2.5 2.9 2.7 2.8 3.3
3.0 5.0 1.0 3.0 3.0
3.0 4.0 0.0 7.0 7.0
150 188 227 312 390
513 643 773 1062 1331
117 147 176 . 234 293
400 500 600 800 1000
3/4 1/ 1" 1" 1" 1'12 "
175 175 200 250 250
7 7 8 10 10
13.0 14.2 13.5 14.0 14.5
5.2 5.7 5.4 5.8 5.9
20 ' 20 20 20 20
8 8 8 8 8
496 511 550 707 780
1093 1127 1213 1559 1720
DATA SHEET MK III GAS MECTRON BURNERS
I HEATER MODEL 100 150 200 300 400 500 600 800 1000
BURNER GS 5 1 GS 5 GS10 GS10 GS 20 GS 20 GS 20 G3 G3
HEAD I mbar 2.50 3.75 1 2 .50 4.25 1
2 . 88 3.25 4.25 6.86 8.09
PRESSURE ins. wg. ; 1.0 1.5 1.0 1.7 1.15 1.3 1.7 2.8 3.3
BURNER AIR SHUTTER 2.0 3.6 2.5 4.0 3.6 4.5 5.5 7.0* 7.0* I
BURNER GAS HEAD 1.8 3.0 3.0 4.0 2.5 3.5 3.9 3.0 3.0
HEATER kW 37 54 74 109 146 184 217 312 390
INPUT Btux10J 127 183 253 372 497 626 739 1062 1331
kW 30 I , 61 176 234 293
HEATER 1 43 87 119 148
OUTPUT Btux 1 O J 103 148 208 297 405 504 599 800 1000
GAS INLET I '12"
I 1W'
CONNECTION V2" 3/.' 3/4 /1 3/4" 1 " 1 " 1"
FLUE SIZE mm 125 125 150 150 175 175 200 250 250
(NOMINAL) ins. 5 5 6 6 7 7 8 10 10
MIN. GAS mbar < 12.0 < 12.0 < 12.0 13.5 < 12.0 12.0 14.5 14.0 14.5
INLET PRESS. ins.wg. i < 5.0 5.0 < 5.0 5.5 < 5.0 5.0 6.0 5.8 5.9
MAX. GAS mbar 20 20 100t 100t 100t 100t 100t 20 20
INLET PRESS. ins.wg. 8 8 40 40 40 40 40 8 8
Kg 208 208 407 407 496 571 550 707 780 WEIGHT
Ibs 1 458 458 897 897 1093 1127 1213 1559 1720
*Internal setting. NOT shutter. t With CG Monobloc gas trains only. Standard gas train value 20mm (8").
7C ELECTRODE SETTINGS
I
Position of the ionisation probe Position of the ignition electrode 2+4mm
v
-+-+---'"-li- E E
+ cry
IMPORTANT Don't turn the ionisation probe, but leave it in the position as shown on the figure above; if moved towards the ignition electrode the amplifier of the control-box could get damaged.
70 IONISATION CURREN.T
The minimum safe level of ionisation current to enable the control-box to operate correctly and detect a gas-flame is 2 uA (two micro amps).
The control box will of course, under normal circumstances, never be required to operate under such a small signal condition, by correctly positioning the flame electrode.
To test the ionisation current (and hence the flame signal strength) a direct current micro-ammeter should be inserted in series with the flame electrode. as per diagram.
Ammeter
--------4c: ----+~BI-----4c: :3 Cable
Flame probe
7E COMBUSTION HEAD ADJUSTMENT - GAS 2 BURNER
Two separate adjustments have to be made. one for the air and one for the gas settings; these are carried out when the firing head is still separate from the burner body, during installation.
Air setting Loosen the screw (1), move the elbow (2) so that its rear (3) coincides with the chosen stop-gate number on the graduate stop-plate scale.
Then tighten the screw (1) with a 6mm AUen Key.
Gas setting Loosen the screw (5), and turn the ring nut (6) so that the pointer (7) coincides with the chosen stop-gate number on the calibrated scale (8).
Then tighten the screw (5).
7F AIR PRESSURE SWITCH ADJUSTMENT
Adjust the setting of the air pressure switch after all other arrangements have taken place, starting from the setting at the bottom of its scale.
While the burner is firing, increase the pressure by slowly turning the reglating knob clockwise, until the solenoids close.
Then, turn the knob back by two turns and restart the burner, thereby checking that it functions regularly; should another closing of the solenoids follow, turn back by one more full turn.
mbar
,- .9 . --; 7 ] Adjustment5 '- •
I • 3 range:--,
Regulatingknob
1 mbar = 1 Omm w.g.
7G MOUNTING - GAS 3 BURNER
I
7H COMBUSTION HEAD ADJUSTMENT- GAS 3 BURNER
Two separate adjustments have to be made, one for the air and one for the gas; these are carried out when the firing head is still separate from the burner body, during installation.
Air setting _ Loosen the two screws (1) and move the internal part of the firing head (2), so that its rear edge (3) is level with the desired set-point on the plate (4). Then retighten the screws (1).
Gas setting Loosen the screw (5), move the ring (6) so that the pointer (7) is level with the desired set-point (8). Then tighten the screw (5).
8 6 5 2
7J SETTING INSTRUCTIONS FOR GRASSLIN TYPE SF SERIES TIME SWITCH
1. Access to the programme dial for time setting To gain access to the programme dial for time seWng remove the Makrolon front cover by lifting off. This exposes the 7 day programme dial and tappet slots on its rim into which the coloured tappets are inserted to suit the switching programme.
2. Programme dial rotation The programme dial is rotated by turning the top minute hand on the clock display in a clockwise di'rection. During this operation a certain amount of noise is emitted from the gear movement as it is rotated but this is normal and is in no way detrimental to the functioning of the control.
The main diall makes one revolution in 7 days with the markings in 24 hour clock system, though the clock display is 12 hour system.
Important: Under no circumstances should the programme dial, be forced round in either direction as damage to the gear assembly and switch will result.
Do not rotate programme dial by hand. Proglramme dial must be advanced by rotating minute hand only.
3. Initial setting procedure (a) Remove all tappets from the dial rim then commence the setting procedure by inserting a 'Green'
tappet embossed '1' into the slot at the required 'ON' time in the Monday segment on the dial, then a 'Red' tappet embossed '0' at the 'OFP time on that day noting that the 24 hour clock is used (6 rel'ates to 6a.m. and 18 relates to 6p.m.). Minimum switching interval 3 hours.
(b) Repeat the operation in (a) for Tuesday, Wednesday etc. even though the 'ON' and 'OFP time may be the same for each day.
(c) Where omission of any day or part is required it is only necessary to leave out completely the tappets for that period as after operation of a 'Red' 'OFP tappet no switching will occur until the next 'Green' 'ON' tappet is operated.
(d) Check the tappet setting to ensure that 'Green' and 'Red' tappets alternate on the di,al and that a 'Green' tappet is always followed by a 'Red' tappet in a switching period. Spare tappets should be placed in the parking holes provided.
(e) Adjust the time switch by rotating the minute hand on the clockface in a clockwise direction until the correct day is opposite the .. on the dial located near the contact position indicator. FinalJ,y set the clock hands to the correct time of day remembering the 24 hour telltale markilllg on each day on the dial.
')P
4. Changing the programme When introducing a change in the switching programme follow the initial setting procedure unless repositioning of the tappets for a change can be effected so that instruction 3(d) stili applies, and that it is for a day other than indicated by the arrow ...
5. Replace the Makrolon front cover ensuring that the notches on the cover locate in the slots in the case.
6. The time switch is now ready for service.
7. Manual override Turning the knob, located at one corner of the time switch, in an anti-clockwise direction, opens or closes the switch contacts from '1' to '0' or '0' to '1' anticipating the next operation. This does not affect subsequent switching programme, as already set.
WARNING: If difficulty is experienced in turning the manual override button, this will be due to the normal operating tappets engaging with the override mechanism. Do not force under these conditions or permanent damage may be caused. Wait for 15-20 minutes or advance the time by 15-20 minutes - see 2 and 3 above to allow the tappet to move from the position causing the problem.
Section Eight - Wiring Diagrams
THREE PHASE AIR HEATER WIRING DIAGRAM
For burner wiring refer 10 Burner Wif ing Diagram
Terminal block ,
In RieHo burner Fan molor 500 I
I
1~
Fan motor 400
Fan molor 600 ! 6.5 amp I Fan molor 800 I 8.4 amp 1
Fan motor 1000 1 1.2 ampI
11
49 amp 1
I
1
I 1
L
I I
IE U I Vlw1NJ I A I 1315 13 1}2 3 4 15 16 17 I Conlactor L
1 OIL relay
21 416 14 B .I"-Supply 2 1 4 I 6 96
95
8~ .--
Summer Fan l- f-
molor ~ f-Ft> OFF r-- Winter
~~sitlon sWitch
-1 ~L
I -
Fan Umlt stal stat
"I ''1
Time J ClI- WRoom
OJ
'" t-r--::: slat
...:
Cj--
It--F n'-h 1::::<ti t:--
I J
1-
FrOSI Sial
I
SINGLE PHASE AIR HEATER WIRING DIAGRAM Indirect drive
OIL RELAY SETTINGS Fan motor 400
REFERFan motor 500
TOFan motor 600
MOTORFan motor 800
PLATE
For burner wIfing refer to Burner Wiring Diagram
Termmal block in Riello burner
l 1 I....--r-"T"""""TL-',--
Fan motor 1000 I
Fan limil Slat stal
n----~h---1.....L..LJ'1
Supply
Fan I--
Contactor
OIL relay
t-OJ
'" :::
21416 14 BI-+-+-+--t-.....J"--214[ 6 961----+-----i--+--++--------'
U 95
.--'-----"""'f- Summer8 '--!-
motor ~I--__ '-----------If-Ft> OFF
r-- Wmter
~~sition sWItch
WRoom~c::RlI slatrr--1L::--n '-h I
L~ I ~__~_______JI L____~
II I
SINGLE PHASE AIR HEATER WIRING DIAGRAM Direct drive-
FAN MOTOR F.LA
Model I Amps
lOa I 2.5
150 I 3.4
200 5.0
300 I 6.0
r ~
Frost sta.t
:-l r
t nn IE ILINI4 156 17 18 191
I I I 240,/·1 PH·50Hz
supply
I IL--_------.J
...----+----1
GSan ;=f-motor j.-f--L.J---l
IL-nll
I L..-: Summer
LI-f--.r--....... OFF
'-------~n~ Winter L
3 Position SWitch
--.J Fan stat
h
L r-Limit stat
r1
1 1 1 1 Termina l block in Riello burner
1
...-~ Room stat
h r I [
J
For burner wiring refer to Burner Wiring Diagram
THREE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL
For Ourner wiring reter 10 Burner Wifing Diagram
7ermlnal bloCk ~ R,ello burner
1~
O: L "IELAY SETTINGS
Fan mo!or 400 Fan mo 'or 500 4 9 amp Fan mo,~r 600 I E 5 amp Fan mOtor 800 I B 4 amp
Fan mOtor t 000 I 112 amp
I) I rE ufvlw f N [A 1 1 31 5 t3
Con:actor
OI L relay
2 14 I 6 t4
Supply ~ .I 4 !6 96
95
GS~ IFan l-motor ~
l I I
~
l 1 t [2 3 41 51[ 6 '1 7 1
U B..J"--
• , .' ,--. Summer
~ft> OFF Winter
G'p;;sltlon sWitch
J w Fan s:al
""l
1Q) <II
.2
..: "' =
L r----Limit stat
I~
[AIS[CIOIE[r-
-~ -
1
SINGLE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL
Direct drive
FAN MOTOR F.LA.
Model Amps
100 2.5
150 3.4
200 5.0
300 6.0
For burner wIring refer to Burner WIring Diagram
Summer
OFF
Wmter
3 POsll lon SWIlch
Terminal blOCM in Riello burner
SINGLE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL
Indirect drive
For burner wlrtng reter 10 Burner WIring Diagram
OIL RELAY SE!TINGS Terminal bloCk
Fan motor 400 In Aiello bu rnerREFER
1
Fan motor 500 TO Fan motor 600 MOTOR Fan motor 800 PLATE Fan motor 1000
I n IE U I v Iw IN IA I I 3 I 5 , '3
1 ContaClor
OI L relay
t 214161,t4
Supply 1 2 14 1 6 ~ 96
U [l5
Fan I(Sil-motor B
I II .
I
I III
l ItJ 2 31 4 I 5 11 617 j
, IU B I"--
O-Summer
I--ft:> OFF
I-- Winter
G'Pc;Sltlon sWIIch
I
l., '" ~ <.; ~
I
~ , L f----Fan Limit Sial I sIal n L~
I A IBI C ~D I EI
1
COMMISSIONING CHECK LIST
Refer to 'Commissioning and Testing' Section Three of this Manual.
CHECK LIST Tick when completed
3B Control Chassis Inspection
3C I Time Switch Adjustment
3D I Room Thermostat Adjustment f-
3F I Fan Limit Thermostat settings
3G I Explosion Relief Door Check
3H I Fan Inspection and rotation check
31 I Flue pipe inspection
3J Combustion Air Supply Check
3K Gas Supply Check
3L Burner Inspection for air and gas settings
3M.3N 30 or 3P Gas Soundness Test
3R Main Burner Gas Setting Pressure, State Pressure in mbar or ins. w.g.
mbar Ins. w.g.
3S Combustion Check State percentage of Carbon Dioxide (C02) at flue outlet of heater %I
3T Set Air Pressure Switch
3U Flame Failure Lock-Out Check
3V All controls adjusted to suit customers requirements
3W Users Instructions handed over to Customer
Representative of Commissioning Organisation
I
Signature
Date
Company
Leave this Commissioning Check List with user. Complete and despatch Warranty Registration/Commissioning card and return to:
BENSON HEA TING LIMITED LUDLOW ROAD,
KNIGHTON, POWYS LD7 1LP
TELEPHONE (0547) 528534 TELEX 35323
FAX 0547520399