GAS FIRED AIR HEATERS

Transcription

1 Installation and maintenance manual GAS FIRED AIR HEATERS FHAR..H/V/C DTC ARM EN 1312BO3933 1

2 TABLE OF CONTENTS Section N Sections Pages 1 GENERAL INFORMATIONS 4 à General recommendations End of life of the product Description of the device Operation Instructions for use Operation Safety Cut-Off Guarantee 5 2 TECHNICAL SPECIFICATIONS OF ARM UNIT HEATERS 6 à Performances FHAR..H Models FHAR..V Models FHAR..C Models 9 à 12 3 MOUNTING OF UNIT HEATERS 13 à Recommendation for use Ajustable rotation console and IPN Kit for ARM 1/2/3/4/4.5/5 H Wall mounted console for ARM 6/8 H Wall mounted console for ARM..C 14 4 ELECTRICAL WIRING 15 à Electrical schematics of the gas heaters AR...H and AR...C Electrical schematics of centrifugal gas air heaters AR6C AND AR8C Electrical schematics for ARM..H and ARM..V gas air unit Basic connection schematic with pilot wire thermostat Basic connection schematic using individual thermostat 18 5 FLUE PIPE CONNECTION 19 à Generalities Connection of single roof flue kit B Connection of concentric roof flue kit C Connection of concentric roof flue kit C GAS CIRCUIT 22 à Changing gas Modulating valve adjustment table 23 7 GAS CONNECTION Connection of unit heaters 24 8 COMMISSIONING OF GAS UNIT HEATERS 24 à Operating principle Bill of material 25 9 MAINTENANCE RECOMMANDATION FOR THE USER TROUBLESHOOTING 27 2

3 NOTICE This technical manual must be kept in good condition inside the appliance. The features, illustrations and descriptions contained in this document are, to our knowledge, accurate at the time of their approval for printing. We reserve the right to modify, to no longer offer certain features or to stop the production of a model without notice and does not constitute any commitment on our part. Security rules - It is forbidden to plug and / or reduce the ventilation openings in the installation room or appliance. - Never obstruct the smoke outlet and fresh air intake. - Never make changes to the settings made by the qualified professional. - Never spray water on the heater, or touch the appliance with wet and / or bare body parts. - Never touch the hot parts of the heater, and / or moving parts. - Do not put or hang anything on the device. - Any intervention on the appliance is forbidden before disconnecting it from the mains and cutting off the gas supply. - Do not change the type of gas used, the device settings, the safety or control systems, as this could create dangerous situations. Notify the service technician in the event of a gas change, gas pressure, or change in supply voltage. In case of a long period of non-operation, disconnect the power supply from the device. When returning to operation, it is advisable to use qualified personnel. In general, any repair or maintenance work must be carried out exclusively by authorized and qualified personnel. Subscription to a maintenance contract is highly recommended, "see with your installer". Caution Electrical components, drive mechanisms and fuel gas can cause injury. To protect against these inherent risks during installation or maintenance, the power supply must be disconnected and the gas supply valve must be closed. All persons involved in the installation or maintenance of this equipment must comply with occupational health and safety standards. What should be done if you smell gas? -Close the external gas valve and the electrical supply then warn the maintenance technician -Do not try to turn on the device again -Do not operate the electrical switch, do not use a telephone located inside the building. -Call your gas supplier from another phone. Follow the instructions provided for your provider. -If you can not contact them, call your fire department. 3

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6 ARM models ARM gas heaters are are equipped with an axial or cebtrigual fan and a 2 stages burner. ARM..H models are intended for horizontal mouting and direct blowing. ARM..V models, are intended for vertical mouting and direct blowing. ARM..C models, are intended for horizontal mouting and duct blowing. 2.1 Performances Gas Input Nominal Output (P rated,h ) Efficiency at Nominal heat output (ƞ nom ) Minimal power (P min ) Efficiency at minimal power (ƞ pl ) Speed rotation Warm Air Flow Delta T of air Reach of air jet Smoke diameter Air inlet diameter Electrical Consumption (Blow fan excluded) At Nominal heat output (el max ) At Minimal power (el min ) Seasonal energy efficiency for space heating (ƞ s,h ) Weight Noise level (fan) at 5 m free 6

7 2.2 ARM..H Models Dimensions : Types FHAR 1H FHAR 2H FHAR 3H FHAR 4H FHAR 5H FHAR 6H FHAR 8H A mm B mm C mm D mm E mm F H mm K mm Ø F mm 80/125 80/125 80/125 80/125 Ø Air Ø G (gaz) 1/2 1/2 1/2 1/2 1/2 3/4 3/4 Weight kg Installation height : FHAR..H models are fitted with M8 crimped nuts on top (except ARM 8 that is below), or fixing the appliance in horizontal mounting Blowing is vertical towards the ground and the installation height must not be lower or higher than that recommended. 7

8 2.3 FHAR..V models Dimensions : I I I I Types ARM 3 V ARM 4 V ARM 5 V ARM 6 V ARM 8 V A mm B mm C mm D mm E mm H mm I mm Ø F mm 80/125 80/125 Ø Air Ø G (gaz) 1/2 1/2 1/2 3/4 3/4 Weight kg Installation height : All ARM..V models are retained at their upper part by four tightened M8 nuts. (except ARM8). Blowing is vertical towards the ground and the installation height must not be lower or higher than that recommended. To get the best performance from these gas destratificators, we recommend you to respect the following heights. 8

9 2.4 ARM..C models Dimensions : A A1 A2 A3 A4 B B1 H L L1 L2 L3 P CAUTION : For ARM 8 C, air intake on the back or on the right side of the box only Assembly of the fan case A B A Fan case B Thermal case The blowing casing (A) is assembled to a thermal casing (B) by four M8 screws (3) which allow an easy dismountling. To access to the cap screws, the closing sheet metal of the casing must be disassembled (1) and (2). CAUTION: the disassembling of the casing must be done only after having cut the power supply. 9

10 Performance of ARM...C centrifugal gas unit heaters TYPES ARM 2 C ARM 3 C ARM 4 C ARM 5 C ARM 6 C ARM 8 C kw-hp / / / (0.75-1) N Type Vitesse A N Type Vitesse A 2* * MV GV * GV * MV 6 10* 10 - PV mm / / / 125 mm Monophase 230 Volts / 50 Hz - IP42 VA kg Flow/pressure curves for ARM..C models Pa * 6 5* * Pa * 10* *

11 ARM model with centrifugal fan and separated motor : Billl of material : Nº Description Nº Description Speed driver access : 1/ 2/ 11

12 Electrical connection diagram : The installation must be in compliance with local standards and/or national regulations. Make sure that the power supply is 230Vac with ground and that it is protected by a fuse. On this centrifugal model with variable air flow, the variation is made thought a speed driver. To access to the speed driver, dismount the protection box. See diagram below: T : Earth - N : Neutral - L : Live - FP : Pilot wire Speed driver setting procedure From the main screen («rdy» if the fan is off, or if the frequence is in progress) : - Press the wheel (picture 1) - The value «ref» is displayed (picture 2), - Press again on the wheel to go to the settings of the frequence percentage - Turn the wheel to modify the value of the setpoint temperature (if the fan is working, modify the frequence in live) - Press twice on ESC button to go back to the main screen. 12

13 2000 mini 2000 mini 200 mini 200 mini 200 mini 200 mini 3. MOUNTING OF UNIT HEATERS (See instructions supplied with the consoles) 3-1 Recommendation for use For good functioning and the security of devices, it s necessary to respect the minimum installation spaces here below: Foresee a minimum space of 200 mm on the back of the unit on the fan side. Foresee sufficient clearance for the opening of the burner door. The heater must be installed at minimum 200 mm from the ceiling and 2000 mm from the floor. 700 mini 200 mini 200 mini 3.2 Ajustable rotation console and IPN kit for ARM 1/2/3/4/4.5/5 H Caution: make sure of the strength of the bracket The CORAT kit is a wall fixing console for gas unit heaters Axial ARM, it can be combined wth IPN Kit for attachment to a metal frame. Attention: The CORAT kit can t be used with ARM 6/8 C. Assembly : See instructions supplied with the consoles. 13

14 3.3 Wall mounted console for ARM 6/8 H Caution: make sure that the bracket is strong enough ARM 6 H ARM 8 H Connection B22 C32 B22 C32 Cote A (mm) Cote B (mm) Cote C (mm) Cote D (mm) The COAT kit is a wall-fixing console for gas unit heaters Axial ARM 6 & 8 Assembly: See instructions supplied with the consoles. 3.4 Wall-mounted console for ARM..C CAUTION : this console is not suitable for assembly with dampers or filter Caution: make sure that the bracket is strong enough ARM 2 C ARM 3 C ARM 4 C ARM 5 C ARM 6 C Connection B22 C32 B22 C32 B22 C32 B22 C32 B22 C32 Cote A (mm) Cote B (mm) Cote C (mm) Cote D (mm) The COAT kit is a wall-mounted console for gas unit heaters type ARM 20/28/35/45/55/75 C. Attention: COAT kit can t be used for ARM 8 C. Assembly : See instructions supplied with the console. 14

15 4. ELECTRICAL WIRING 4-1 Electrical schematics of the gas heaters AR...H and AR...C RFP 4-2 Electrical schematics of centrifugal gas air heaters AR6C and AR8C RFP 15

16 4.3 Electrical schematics for ARM...H and ARM...V gas air unit RFP Only for ARM..V models The modulation thermostat bulb (Mod) is placed on the fan basket for the ARM..V models and in the airflow for the other versions. VT RFP Fan blower Pilot wire receptor MVE PA Smoke extractor Burner pressure switch Limit Overheating thermostat with manual reset SI Ionization sensor Fan Fan triggering thermostat EA Ignition sensor Reg Mod CC Burner regulation thermostat Burner modulation thermostat (modulation option) Control box with isolating transformer EVR EVG Modulating valve gas (2 stages) Gas valve Pilot wire receptor (RFP) Power connector Burner connector Fan connection Burner default Burner Reset 16

17 4.4 Basic connection schematic with pilot wire thermostat Switch off proximity items 2 - Unit heaters 3 Thermostat BSAT4P TFP1 TFP2TS TFP3TS - The AR gas unit heaters are equipped as standard with a receiver for pilot wire, which enables using a single conductor to carry the functions of the ambient thermostat, the forced ventilation and remote resetting. - Several models of thermostat (3) are available. The use of these thermostats will provide you with supplementary functions such as remote resetting and forced ventilation. 17

18 4.5 Basic connection schematic using individual thermostat REG110 REG111 REG112 REG110 Modèle : REG110 REG111 Modèle : REG111 All ARM gas unit heaters are equipped as standard with a receiver which enables the regulator to be connected directly with FLEXIHEAT individual control. Several models of individual thermostats are available: REG110 and REG111 1) Replace the four conductor supply cable with the five conductor cable supplied with the regulator. 2) Make a connection of individual thermostat REG according to the technical manual Individual control box supplied with the gas unit heaters. 3) Connect the 230 V AC power supply of the unit heater. 18

19 5- FLUE PIPE CONNECTION 5.1 Generalities During the commissioning and the maintenance, make sure that: - Combustion air intake and fumes smoke exhaust are not obstructed. - For concentric installation, check that the 2 circuits (combustion air intake and smoke exhaust) are well separated and sealed. Check also the installation of flue pipes and seals. - Seals are not damaged during the installation of flue pipes, between them or on the unit. Ensuring the tightness. - There is no water which can come inside the unit by the flue pipes (electrical hazard). For this, use: drain tee, condensate drain pan, -For big extension and concentric installation, it is necessary to foresee a condensate drain. 5.2 Connection of single roof flue kit B22 The combustion air is taken directly into the locale and the smoke exhaust is done to the exterior thanks to a single flue through the roof. 3 7 Axial and centrifugal heaters Standard connection : - 1 tee with airtight plug (4), - 1 single extension of 1m (5), - 1 single roof terminal (3) with flashing and 1 sliding (7) The roof outlet must be located at least at the ridge height For 1/2/3/4 models, the standard connection is realized in diameter For the model 4.5, the standard connection is realized in diameter For 5/6/8 models, the standard connection is realized in diameter Vertical heaters 7 Standard connection : - 1 single elbow at 90 (1), - 1 single extension of 1m (5), - 1 tee with airtight plug (4), - 1 single extension of 1 m (5), - 1 single roof terminal (3) with flashing and 1 sliding (not including in the kit) (7) The roof outlet must be located at least at the ridge height. - For the models 3 & 4, the standard connection is realized in diameter For the model 4.5, the standard connection is realized in diameter For 5/6/8 models, the standard connection is realized in diameter CAUTION Foresee an sufficient ventilation into the locale. The required fresh air for combustion must be at least of 100 m 3 /h per unit. The section of flue must be at least equal to the diameter of the heater outlet. The smoke exhaust cannot be vertical or at 45 minimum. The total length of the connection cannot exceed 6 m, knowing that : elbow 90 or 45 = 1 m of flue. If the outside part of the flue is higher than 2 m, foresee an insulated pipe. 19

20 5-3 Connection of concentric wall flue kit C12 The connection for combustion air intake and smoke exhaust is made horizontally towards the outside of the room. Correct assembly Incorrect assembly NO For direct concentric wall connection, the installation must be realized with an opposite slope at the unit of 2 minimum. Axial and centrifugal heaters Type of mounting for ARM1/2/3/4 (concentric connection ø 80/125) - 1 concentric wall terminal (8) - 1 concentric extension (2) Type of mounting for ARM 4.5 (2 pipes connection on the units 2 x ø 100) - 2 single extensions (5), - 1 concentric wall terminal (8). Type of mounting for ARM 5/6/8 (2 pipes connection on the units 2 x ø 130) - 2 single extensions (5), - 1 concentric wall terminal (8). The use of flues involves a parfait sealing. To facilitate the installation, it is necessary to use a lubricant, non-agressive for the gasket, example: soapy water. CAUTION The junctions must be sealed and rigids. The section of flue must be at least equal to the diameter of the heater outlet. The smoke exhaust cannot be vertical or at 45 minimum. The total length of the connection cannot exceed 6 m, knowing that : elbow 90 or 45 = 1 m of flue. If the outside part of the flue is higher than 2 m, foresee an insulated pipe. 20

21 5-4 Connection of concentric roof flue kit C32 The connection for combustion air intake and smoke exhaust is made vertically towards the outside of the room. 7 Axial and centrifugal heaters Type of mounting for ARM 2 & 3: ( Concentric connection on units ø 80/125 ) - 1 concentric elbow at 90 (1) - 1 concentric extension (2) - 1 concentric roof terminal (3) with flashing and 1 sliding (7) Standard connection for ARM 4.5 (2 tubes connection on units 2 x ø 100) - 2 single elbows 90 (1) - 2 single extensions - 1 concentric roof terminal (3) with flashing and 1 sliding (7) Standard connection for ARM 5/6/8 (2 tubes connection on units 2 x ø 130) - 2 single elbows 90 (2) - 2 single extensions - 1 concentric roof terminal (1) with flashing and 1 sliding (7) The extension of concentric flue is limited to 6 m. Vertical heaters Type of mounting for ARM 2 & 3: (Concentric connexion on unit ø 80/125) - 1 condensate drain pan 6) and 1 single extension (5) - 1 concentric extension (2) - 1 concentric roof terminal (3) with flashing and 1 sliding (7) Standard connection for ARM 4.5: (2 tubes connection on units 2 x ø 100) - Condensate drain pan (6) and single extension(5), - concentric roof terminal (3) with flashing and 1 sliding (7). Standard connection for ARM 5/6/8 (2 tubes connection on units 2 x ø 130) - Condensate drain pan (6) and single extension (5), - Concentric roof terminal (3) with flashing and 1 sliding (7) The use of flues involves a parfait sealing. To facilitate the installation, it is necessary to use a lubricant, non-agressive for the gasket, example: soapy water. CAUTION The junctions must be sealed and rigids. The section of flue must be at least equal to the diameter of the heater outlet. The smoke exhaust cannot be vertical or at 45 minimum. The total length of the connection cannot exceed 6 m, knowing that : elbow 90 or 45 = 1 m of flue. If the outside part of the flue is higher than 2 m, foresee an insulated pipe. 21

22 6. GAS CIRCUIT 6-1 Changing gas The unit heaters are equipped with atmospheric gas torch burners, permitting the use of Natural gas G20, Natural gas G25 and Propane. The combustion ports are engineered so as to ensure very good stability of the flame without separation or return towards the injectors. The service visits must be carried out by a qualified professional person. Changing the gas is carried out in the following manner: 1- Disconnect the electrical supply connector and close the gas inlet. 2- Unscrew the gas line fixing nut (Item 1) on the gas valve and also the three screws (Item 2) which retain the injector ramp on the burner block. 3 Change the injectors (see adjustment table). 4 Screw in the new injectors (Item 3) changing the seals (Item 4) and making sure concerning sealing. The injectors must be installed dry. 5 Reassemble the ramp and connect the gas line to the gas valve, replacing the seal, make sure during assembly not to forget, or damage the seal. 6 Check for sealing after assembly. 7 Adjust the gas ramp pressure on the regulator. CAUTION : The adjustment of the gas pressure is made with the burner running Adjusting the gas pressure is done in the following manner: 1 Open the solenoid valve pressure regulating protection screw. 2- Unscrew the pressure test point, connect the pressure gauge (5) 2- Adjust the ramp pressure (6), in accordance with the adjusting table After adjustment, do not forget to put the protective screw back in place and to close the pressure test point. 6 Check for sealing after making the adjustment. 5 22

23 6.2 Modulating valve adjustment table Gas valve 20 to 75 kw Gas valve 90 kw 8 (High Speed) 7 (Low Speed) Pressure test 8 7 (High Speed) (Low Speed) Pressure test ATTENTION, Belgium and Luxembourg: The change of gas is forbidden. Only the manufacturer is authorized to operate a transformation of the device 23

24 7- GAS CONNECTION A precise engineering study must be carried out on the diameters of the piping depending on the nature of the gas flow and the length of the piping. Make sure that the pressure drops in the piping do not exceed 5 % of the supply pressure. The gas connections must be carried out in conformity with the requirements concerning interior installations regardless of the type of gas. 7-1 Connection of unit heaters The unit heaters operate with a pressure of between 20 and 25 mbar for Natural gas and 37 mbar for the Propane versions. 1/ The gas supply network pressure corresponds to the entry pressure of the device: - in this case, connect each device with a dam valve item 1 and the gas filter item 2. 2/ The gas supply network pressure is higher than the intake pressure of the device: - in this case, connect each device with a dam valve item 1, a gas filter item 2 and a pressure regulator item 2, to reduce the supply pressure to the unit heater. CAUTION Any supply pressure which is higher than the maximum intake pressure tolerated by the gas solenoid valve will cause irreparable damage to that solenoid valve. To connect the unit heater to the gas network, use the union item 4 with the seal item 5 delivered with the device. Tighten the union onto the network before connecting it to the unit heater. Check that the gas supply circuit is correctly sealed upto the gas solenoid valve. (see schematic) Network Check the sealing up to the gas solenoid valve input 8- COMMISSIONING OF GAS UNIT HEATERS 8-1 Operating principle: 1- For the commissioning of the device, turn the regulation to demand. The inspection box tests the air pressure switch contact switch in its at rest position, and then triggers the smoke extractor. Its correct functioning is controlled by the differential air pressure switch which, if there is not enough air, will prevent the control box from following its cycle. 2- After pre-ventilation, the ignition electrode lights up and the gas solenoid valve allows the gas to pass to the injectors. 3- If the air/gas mixture is not ignited or is not detected by the ionisation sensor, the flame control box tries once more and then changes to safety position. 4- Once the burner is ignited, the blowing fan is triggered when the air temperature is higher than the fan airstat regulation value (35 C to 40 C). 5- In the case of a fan malfunctioning, the excess heat safety thermostat cuts off the unit heater burner if the temperature exceeds 90 C. CAUTION : Never stop the device before the fan has totally stopped. The lack of cooling can necessitate the excess heating airstat to be reset and can damage the heat exchanger over the long term. 24

25 8-2 Bill of material Détail carte RFP (24) A- Détail connexion AR 1/2/3/4 A- Détail connexion AR 5/6/8 No. Description Spare parts part number ARM 1 ARM 2 ARM 3 ARM 4 ARM 4.5 ARM 5 ARM 6 ARM 8 1 ATE131 ATE131 ATE131 ATE131 ATE004 ATE260 ATE260 ATE260 2 ATE167 ATE167 ATE168 ATE169 3 ATE132 ATE132 ATE132 ATE132 ATE004 ATE260 ATE260 ATE260 4 ATE801S ATE801S ATE802S ATE803S ATE804S ATE804S ATE807 4 ATE065 ATE061 ATE061 ATE063 ATE063 ATE194 5 ATE212 ATE212 ATE212 ATE212 ATE212 ATE212 ATE213 ATE213 6 GAZ0102 GAZ0105 GAZ0105 GAZ0105 GAZ0102 GAZ0102 GAZ0102 GAZ GAZ0011 GAZ0014 GAZ0103 GAZ ATE021 + ATE ATE022 + ATE024 ATE022 + ATE ATE ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE ATE147 ATE147 ATE147 ATE147 ATE147 ATE147 ATE147 ATE ATE204 ATE204 ATE204 ATE204 ATE204 ATE204 ATE204 ATE SE0506 SE0411 SE0420 SE0403 SE0430 SE0439 SE0448 SE ATE002 ATE002 ATE002 ATE013 ATE013 ATE013 ATE112 ATE ATE201 ATE201 ATE201 ATE201 ATE201 ATE201 ATE201 ATE ATE521 ATE521 ATE521 ATE521 ATE521 ATE521 ATE521 ATE ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE146 ATE AT1628 AT1628 AT AT4228 AT4228 AT AT4435 AT4435 AT TUB003 TUB003 TUB ATE407 ATE407 ATE ATE410 ATE410 ATE410

26 9-MAINTENANCE Correct and regular use and maintenance of the unit heater will determine rational and efficient operation, minimum consumption as well as long life. The maintenance must be done with the device cold, with the gas and electricity supplies cut off. These service visits must be carried out by a qualified professional person Parts Maintenance operations Unit heater Check the correct functioning of all the safety devices and verify that all the screws are correctly tightened. Heat exchanger, smoke extractor and venturi Get access to the heat exchanger by disassembling the burner and smoke boxes, clean it. Clean the extractor and the venturi via the rear smoke connection. Fan Clean with compressed air Smoke conduit Disassemble the conduit and sweep it out Blowing cases and grilles with adjustable vanes Clean using a duster Burner torches Disassemble the burner ramp, check their condition and clean them Injectors Clean the gas injectors Ionisation sensor and electrodes Check their condition, change them if necessary. Gas filter Disassemble the dirty cartridge and clean it with compressed air 10- RECOMMENDATIONS FOR THE USER Precautions to be respected : - Never obstruct the evacuation of the smoke and the intake of new air. - Never make any modifications to the adjustments which have been carried out by the qualified professional person. - Never spray any water onto the gas heater - Warn the after-sales technician when there is a change of gas, of gas pressure or a modification of the power supply voltage. You are strongly recommended to take out a maintenance contract: see with your installer. What should be done in case of problems? PROBLEMS REMEDIES 26

27 11- TROUBLESHOOTING In case of problems, make sure that the conditions required prior to operating the unit heater are present. If the control box is in the safety position (with the burner defect indicator lamp lighted up), reset it. CAUTION : All electrical or mechanical operations must be carried out when the electrical supply is cut off and the gas supply is closed. Defect Cause Remedy 27

28 Flexiheat UK Ltd, Unit 49 Azura Close, Woolsbridge Industrial Estate, Three Legged Cross, Dorset, BH21 6SZ Tel: Fax: