K X V and K X O WALL SERIES HOT AIR GENERATORS USE & MAINTENANCE HANDBOOK

Transcription

1 HEAD OFFICE : VIA BIBAN 56 ( Z.I. ) CARBONERA TREVISO - ITALIA TEL FAX = info@bpstecnologie.com K X V and K X O WALL SERIES HOT AIR GENERATORS USE & MAINTENANCE HANDBOOK K X 5 & K X 8 Models N.B.: THIS HANDBOOK ATTAINS TO THE GENERATOR ONLY. PLEASE ALSO REFER TO THE BURNER S MANUAL. THE INSTRUCTIONS HEREIN INCLUDED APPLY ONLY TO THE COUNTRY MARKED ON THE APPLIANCE LABEL. 1

2 CONFORMITY DECLARATION We, undersigned, B.P.S. PRODUZIONE s.r.l. DECLARE that the K X -V and K X -O Series Hot Air Generators have been duly manufactured in compliance with the 90/396/CEE and the 89/392/CEE gas standards and also with the European Pr EN 1020 standard of 1993 and following changes. TECHNICAL DATA MODEL K5X-V* K5X-O* K8X-V* K8X-O* CE GAS CERTIFICATION CE NOMINAL THERMAL INPUT kw NOMINAL THERMAL OUTPUT kw THERMAL EFFICIENCY µ % FUEL CONSUMPTION FIGURES at + 15 C TREATED AIR METHANE G20 (9.45 kw) m 3 /h METHANE G25 (8.12 kw) m 3 /h PROPANE G31 (12.8 kw) Kg/h BUTANE G30(13.8 kw) Kg/h GAS OIL (11.8 kw) Kg/h DELIVERY at +20 C m 3 /h WORKING STATIC PRESSURE Pa TEMP. RISE C N CENTRIFUGAL FANS rev/ ELECTRICAL SUPPLY V/AC Hz INSTALLED ELECTRIC POWER Watt SOUND LEVEL at 3 m. IN STANDARD INSTALLATION db (a) WEIGHT Kg REQUIRED AIR VOLUME FOR COMBUSTION m 3 /h SMOKES MASS DISCHARGE g./sec * V = Vertical *O = Horizontal COUNTRY CATEGORY FEEDING PRESSURE in mbar G 20 G 25 G 30 G 31 ITALY II 2H FRANCE 11 2Er BELGIUM I 2ErB/I SPAIN II 2H HOLLAND II 2L3B/P PORTUGAL II 2H GERMANY II 2ELL3B/P GREECE I AUSTRIA II 2H3B/P SWITZERLAND II 2H3B/P

3 K X V HANGING HOT AIR GENERATOR MODELS GLOBAL VIEW MODEL A B C D E F G H I ØL ØM N O P Q R K5X-V K8X-V Pict.1 3

4 K X O HANGING HOT AIR GENERATOR MODELS GLOBAL VIEW MODEL A B C D E F G H I ØL ØM N O P Q R S K5X-O K8X-O Pict.2 4

5 INSTALLATION EXAMPLES SHOWING EXHAUST & SUCTION DUCTS AND THEIR MAXIMUM ALLOWED LENGTHS 5 Pict.3

6 INSTALLATION EXAMPLES Pict.4 6

7 7 Pict.5

8 These are independent, forced convection heating appliances, equipped with fan, that can work with blown air gas or gas oil burners, designed for room heating. They are divided in 4 categories, depending on the installation system : 1. C 13 type : sealed with respect to the installation room, separate combustion air suction pipe and combustion products exhaust pipe, wall outlet. (Pict.3) 2. C 33 type : sealed with respect to the installation room, separate combustion air suction pipe and combustion products exhaust pipe, roof outlet. (Pict.3) 3. C 53 type : sealed with respect to the installation room, separate combustion air suction pipe and combustion products exhaust pipe, roof outlet or flue. (Pict.3) 4. B 23 type : combustion air suction from room and combustion products exhaust through roof outlet or flue (Pict.3) WARNING Please carefully read all the instructions given in this booklet, as they ll be all very useful for both safe installation and proper use & maintenance operations. Installation is to be carried out always strictly complying with the current standards of the country where the appliance is going to be used and following, of course, the instructions given by the maker. Only skilled operators and Authorised Assistance Centres will be entitled to carry out installation. Please note that, should wrong installation cause harm to people or damage things, in no way the manufacturer will be held responsible for it. Before opening, check well packing cardboard box and its contents. If any doubt, don t use the unit but contact the supplier first. Always keep packing parts away from children reach, as they may be harmful. Keep suction grids clear. In case of breakdown or failure: turn unit off, do not try to repair it on your own, call operator. If you are going to leave the generator off for a long time, first make sure that in no way this could cause harm to anyone in any way. This unit was designed to be used for heating purposes only. Any different use is not allowed as it may be dangerous. Always keep this handbook with the unit. Should the unit work in a house where disabled people and/or children live, it must be placed safely away from their reach. Always make sure that the access door to the inside control board stay locked. GAS ESCAPE In case of typical gas smell, do not turn on electric switches nor use telephone or any other appliance that could produce sparkles. Quickly open doors and windows to let fresh air in, lock the gas detecting hand-valve and call for qualified operator. PERFORMANCE The K X hot air hanging generator is an appliance that heats room air by exploiting the thermal energy resulting from combustion. This thermal exchange is obtained by a no-stop air jet lapping the heat-exchanger areas. The air jet comes from a centrifugal fan, without need of intermediate fluid. Thanks to their high heat performance (> 90%), safe working, low noise level, quick setting-up, the K X series units are the best for industrial plants, warehouses, gyms, greenhouses, swimming pools, and so on (however they should never work in places directly subject to atmospheric conditions). GENERAL MANUFACTURING FEATURES HEAT EXCHANGER ( 4 SMOKES REVOLUTIONS) Made of welded stainless steel sheet, sealed tested to meet the current European standards, easy to check for standard cleaning and maintenance operations: a) Combustion chamber made of Aisi 430 stainless steel sheet, circular section, of suitable thickness and volume. b) Wide surface exchanging elements made of low thermal load high quality stainless steel, rhomboid section, granting lower resistance to air cooling and improved thermal efficiency. c) High quality stainless steel rear smokes collector, with wide inspection door for easy checking and cleanings of the exchanger. d) High quality stainless steel front smokes collector, which opening is closed by safety disk of suitable features, acting as overpressure valve. 8

9 OUTER CASING No visible panel fixing parts : this gives the machine a new fashionable look, while enabling very easy checking too. The outer casing is made of removable panels made of pre-varnished galvanised sheet, with an upper protective film. - The burner housing is totally sealed with respect to the room. Checking door. - The areas the most subject to radiant heat by the exchanger are provided with noise and heat proof insulation - Baffle for air flow direction, double range of vertical and horizontal wings, each one adjustable to improve even air flow diffusion. VENTILATION UNIT It is made of two low noise centrifugal fans, with built-in engine, granting great air delivery. They are provided with mesh safety panels for accident prevention. BURNER UNIT It s made of: - Hooking plate with peep-hole to check electrodes and flame. - Certified blow type burner, gas or gas oil working (option on request). CONTROL AND SAFETY THERMOSTATS The generator is provided with three thermostats which are already assembled and electrically connected, as follows : - "Fan" thermostat, liquid expansion type. It starts up the fans when average air temperature is approx. 40 C, to avoid cool air getting into the room, then it turns them off when burner goes off, when the temperature raises to 40 C. - Limit thermostat, liquid expansion type. It stops the burner when the average air temperature gets approximately over 80 C. - Maximum thermostat, hand reset, liquid expansion type: it definitely stops burner in case of anomalous air overheating. If necessary, you can reset it by hand by pressing the key, however only after detecting and removing the reason of such anomalous behaviour. OPTIC SIGNALLING UNIT - Green light, to show correct working. - Red light, it shows any electronic board blockage. OPENING for SMOKES EXHAUST The combustion products are exhausted outside through a round opening on the appliance, to be connected to a metal pipe in the permanent way. This pipe must be sized as follows : - It must have wider or same diameter than the opening, with no section reduction.. - Smooth inside surface. If wrinkled flex pipe was to be used, first make sure that the increased loss of load would not involve unhealthy combustion conditions and too much of a counter-pressure inside the combustion chamber. Please check the burner s working field in the attached manual. - With the C13 and the C33 types the length must not exceed 4 m. (please remember that an elbow is equal to approx m. of straight pipe). - With the C53 and the B23 types, please remember that the length must not exceed 6 m. (please remember that an elbow is equal to approx m. of straight pipe). COMBUSTION AIR INLET The combustion air gets in through a circular opening, protected by a net made of meshes smaller than 16 mm.. If the appliance was installed in a place with no air intakes from outside, the combustion air intake too must be connected to the outside, to grant a sealed chamber performance. The same has to be done in case of an under depression room, or a dusty room, to avoid any anomalous working of the burner or the flooding of it. The installation system length must not exceed 4 m. ( keeping in mind that each elbow is long about 0,8-1 Mt. of straight pipe) and should be provided with an outside protecting terminal top the obstruction section of which must not be wider than 40 cm 2. FLUES - All flues have to be made complying with the standards of the country where the generator is going to be used - Every appliance should be provided with its own flue. - The minimum diameter should never be under 220 cm 2. - Every flue should be provided on the bottom with a special chamber for collecting and exhausting the liquid waste stuff. - With gas oil working appliances always remember that the flue width must never be smaller than the joint to the chimney. We recommend in fact to make the flue a 15-30% bigger, and well refined. 9

10 - With gas working appliances, the flue diameter must be long 4 cm 2 per each installed power kw. - The flue must be insulated so that the temperature will decrease less than one degree per meter. - The chimneys openings must exceed one meter the top of roof, parapet or any obstacle standing at least 10 meters away. OPTIONS FEATURES - upon request To make the generators installation easier, the following options are available : ducts, elbows, windproof terminals for air suction and smokes exhaust. Just specify required pieces and sizes when ordering. Adapter: made of galvanised steel sheet : by this one flue diameter and combustion air suction opening can be adjusted to fit any size available in Europe, as required by the EN rule of Shelves : made of painted pressed stainless steel. Wall hooking plate. Fireproof shutter for air recycling and delivery (REI 120 certified) : it stops the generator air delivery and suction circle, when the temperature is over than required. It is made of a rotating blade made of cardboard plaster, some blade rabbet fillets in the shut position, a control device including a set/reset lever, a return spring, a magneto-thermal switch with fuse being set at 70, and a galvanised stainless steel supporting structure with 40 mm flanges. Ready for canalisation connection : we recommend to set a micro-switch connected online to the burner, so to open the circle when the shutter is working. SHIPPING & PACKAGING Our KX wall hanging appliances are delivered on pallet; accessories are packed separately. Shipping, unloading and handling of the goods are all operations to be made very carefully in order not to damage goods : always handle the appliance from the bottom only. INFORMATION for SKILLED INSTALLING OPERATORS Install the appliance strictly complying with the rules in force in your country! When choosing the place where to install the unit please keep well in mind the following points : The appliance must never be placed inside wall recesses It must be fixed 2,5-3 Mts. up the floor, so that the air flow would not be shot onto the people in the heated area Always grant easy connection to the fuel mains Always grant easy connection between appliance and smokes exhaust and combustion air suction pipes If required by law, make necessary ventilation holes The working temperatures field must be between 5 C and + 40 C There must be no obstacles too close to the generator as this would affect the proper hot air diffusion, complying with the current laws and safety rules in gas operated thermal plants The generator is usually placed on wall hanging shelves ( the leaning point must only be the bottom of the appliance) to be conveniently fixed to a suitable structure, keeping the minimum distances from walls and ceilings, in order to : - grant the safe recycling of the air to be heated; - make cleaning and maintenance operations easier; - avoid depression that would rise in case the appliance was too close to ceiling and wall, which would inhibit the correct air cooling inside the combustion chamber. In case holes were made across flammable walls, please note that an insulation must be provided around the smokes exhaust of the size of 5 cm at least. Please note: - Before installing the unit, make sure with the Local Gas Supplying Agency that the maximum gas capacity is actually available for the unit, and that mains pressure and kind of gas are compatible with the data stated in our Technical Data Table here above. POWER CONNECTIONS (without summer ventilation) This unit has been manufactured in compliance with the CEE 73/23 standard, working with a current of 220/230 V/AC Hz. Connection must be made by means of a H05 VV-F cable, 3+4 pole or 7 pole, section not less than 2,5 mm 2. Connect through the proper terminal box, inside the appliance (pictures 6-7) strictly attaining to the wiring diagram and the lettering printed under the box (wiring diagram on page 16). STANDARD CONNECTION = Compulsory earth connection (yellow-green wire) ph = Active phase connection N = Neuter phase connection 2 = Connection to the burner - neuter; 3 = Connection to the room thermostat and burner phase; 10

11 4 = Connection to the room thermostat; 5 = Connection to the blockage light. POWER CONNECTIONS (with summer ventilation) This unit has been manufactured in compliance with the CEE 73/23 standard, working with a current of 220/230 V/AC Hz. Connection must be made by means of a H05 VV-F cable, 3+5 pole or 8 pole, section not less than 2,5 mm 2. Connect through the proper terminal box, inside the appliance (pictures 6-7), strictly attaining to the wiring diagram and the lettering printed under the box (wiring diagram on page 17). = Compulsory earth connection (yellow-green wire) ph = Active phase connection N = Neuter phase connection 1 = Connection to summer ventilation 2 = Connection to the burner - neuter 3 = Connection to the room thermostat and burner phase 4 = Connection to the room thermostat 5 = Connection to the blockage light. WARNING : The neuter-phase connection must be absolutely correct. Any failure to observe the correct polarity will make the appliance block up. We recommend to make the connection preferably in the permanent way by means of a magneto/thermal switch of suitable power. The contacts should be 3 mm. open at least. The omnipolar switch or the plug (connection by means of cable and plug) must be mounted in places easy to reach. INSTALLATION & CONNECTION OF THE REMOTE CONTROL BOARD (option) Connect the remote control board (optional) on the special plug, on positions 1 e 2, keeping the power diagram and the numbers as printed on the same terminal panel. It has to be set in a place where there is constantly a medium temperature, between 1,5 and 1,7 Mts. from the floor. HOW TO CHOOSE THE BURNER To ensure proper unit working, burner s flame pipe must be at least as long as the depth of the combustion chamber mouth (mm.60) and the pressure value for the available combustion air must be higher than take-off and operating pressure values inside the combustion chamber (Pa 30). Before choosing it, make sure that the value is Pa 30 and attain to the pressurisation diagram as given in burner handbook. WARNING : The correct adjusting of the burner thermal capacity will depend on whether this adjusting was made by a qualified installing operator or not. The maker cannot be held responsible for any direct damage resulting from wrong installing or adjusting. FIRST START - GAS WORKING BURNER To carry out the first start-up please follow the instructions below: Check that the control board main switch is off. Open gas tap and let air leak out from the pipeline, if necessary (see burner manual) Give voltage Remove any blockage (see burner manual) Adjust burner to the required output (see burner manual) Make sure that the gas consumption figure, the one you now read from the gas meter, does correspond to the one stated in the manual or on the appliance plate When all the adjustments are made, it is compulsory to seal all adjusting devices (example : paint drop) FIRST START - GAS OIL WORKING BURNER To carry out the first start-up please follow the instructions below: Check that the control board main switch is off. Make sure that the burner nozzle output and other features were as per manual and that thermal output was as stated in the manual or on the appliance plate. Open gas oil tap and let air leak out from the pipeline, if necessary (see burner manual) Give voltage Remove any blockage (see burner manual) Adjust burner to the required output (see burner manual) Make sure that, when burner is working, the pump pressure is as stated in the manual. AND NOW THE UNIT IS READY TO WORK. 11

12 PLEASE NOTE : THE ROOM TEMPERATURE MUST BE SET ON THE ROOM THERMOSTAT ONLY AND NOT ON THE APPLIANCE THERMOSTAT. STANDARD MAINTENANCE OPERATIONS In order to grant the appliance always the best performance and upkeep, timely carry out maintenance operations at least once a year, we suggest at the end of the cold season. All maintenance operations can be carried out only when the appliance is cold, provided the electric power is disconnected and the gas or gas oil tap shut. CLEANING THE EXCHANGER WHEN THE WINTER SEASON IS OVER For this operation just take the following steps: Take burner out of its housing. Remove rear panel from the appliance, remove inspecting door placed in front of the exchanger. Clean exchanging elements by using a stainless steel tube brush. By a vacuum cleaner remove any soot from combustion chamber, coming from exchanging elements. Also clean exchanger outer areas. If necessary, replace little inspection door gasket, in order to ensure always perfect sealing. CLEANING THE BURNER See burner manual. FAN KEEPING Check that no dirt was left on it. Clean it by a vacuum or compressed air pump. HEATING FAN Remove it and clean it well by a paintbrush or compressed air. TROUBLESHOOTING - CAUSES & REMEDIES In case of malfunctions in the hot air generator, first check the following points: - Power must be connected. - No voltage jumps exceeding +10% / -15%. - Fuses must be in order. - There must be enough gas or gas oil available. - Pressure and output of gas or gas oil must be exactly as stated in our technical features table. Here below please find a troubleshooting list, where you can find possible causes of the trouble and look up suggested remedies in order to restore the correct performance of the unit. MALFUNCTION POSSIBLE CAUSE REMEDY Fans do not start. - No voltage - Check main switch position. - Check line Check connections. - Check fuses. - Fan thermostat being damaged - Replace it Exchanger overheating - Burner providing too much heat - Set as per plate values. - Air fans out of work - Check power connections - Fan damaged, replace it - Air suction choked - Remove choke - Too big choke in delivery - Remove choke Burner does not start - Hand reset thermostat set on - Set it off Burner setting the reset thermostat on Burner stopping when normally working, even when room temperature lower than set by thermostat Unit working no-stop, but temperature staying lower than scheduled - Too big choke in air delivery, over thermostat bulb - Room thermostat being damaged, or placed in the wrong way - Unit thermal power too poor to heat the room - Remove choke - Remove it or place it in the correct way. - Replace unit by another one having suitable thermal power.

13 See before - Consumption lower than required - Adjust it to plate figure. - Dirty exchanger - Clean it. Unit producing steam and getting dirty - Too short gas oil consumption - Adjust to plate value. PLEASE NOTE : ALL REPAIRS MUST BE CARRIED OUT BY QUALIFIED SKILLED TECHNICAL PERSONNEL ONLY. ONLY ORIGINAL SPARE PARTS CAN BE USED. IT IS NOT ALLOWED TO OPEN THE UNIT OR TAMPERING WITH UNIT COMPONENTS, OTHER THAN RECOMMENDED MAINTENANCE PARTS. INFORMATION FOR THE USER This appliance has been designed to be used on industrial plants, trade buildings, artisan workshops, warehouses, gyms, hothouses, pools, and many other public places, except for homes. Also, never use it in open-air. WORKING STAGES - Put main switch on (if any). - Open gas or gas oil tap. - Schedule room thermostat at the required temperature. - The appliance now becomes automatic in all its functions. The burner starts and, after a pre-washing time, it starts running. A few minutes after burner s start, fan will start working too, blowing hot air into the room. As soon as room temperature will raise to the figure scheduled on room thermostat, burner will stop and - about 4 minutes later - fan will stop too. This full cycle will be automatically repeated from the beginning, every time room temperature goes below the temperature scheduled on the room thermostat. STOP or TEMPORARY STOP To stop the appliance, just turn off room thermostat switch or summer/winter switch if any. WARNING : DON T CUT OFF VOLTAGE WHEN THE APPLIANCE IS HOT AND THE FAN WORKING. This because the thermal energy stored inside the exchanger would activate the safety LIMIT thermostat, so it would become necessary to reset it by hand. Also, this wrong operation would involve overheating to the heat exchanger. REST AT THE END OF THE COLD SEASON - When the cold season is over, take current off definitely, by depressing the main switch. - Shut gas or gas oil tap. ASSISTANCE You can ask for technical assistance either contacting your retailer or applying direct to: who will give you the address of the assistance service nearest to you. 13

14 K 5 X - V & K 8 X V MODELS GLOBAL VIEW LEGENDA: 1- SMOKES EXHAUST WAY OUT 2- AIR SUCTION INLET 3- CHIMNEY COLLECTOR 4- BLOCKAGE SPY LIGHT 5- WORKING SPY- LIGHT 6- SUPPORT FOR BRACKETS 7- AIR BAFFLES 8- FIRE PLACE 9- EXCHANGER 10- NOISE/HEAT INSULATOR 11- FAN 12- HEAT INSULATOR 13- CHAMBER CHECKING PEEP- HOLE 14- BURNER SUPPORT PLATE 15- ELECTRONIC BOARDS SUPPORT PLATE 16- TERMINAL BOX WITH FUSE 17- BURNER THERMOSTAT 18- FAN THERMOSTAT RESET THERMOSTAT 20- KEY LOCK 21- SEALING PROTECTION 22- CHAMBER BRACKET SUPPORT 23- INSIDE AIR BAFFLE 24- DOOR FOR CHECKING AND CLEANING 25- FAN BULB 26- LIMIT BULB 27- RESET BULB Pict. 6

15 K 5 X - O & K 8 X O MODELS GLOBAL VIEW LEGENDA : 1- SMOKES EXHAUST WAY OUT 2- AIR SUCTION INLET 3- CHIMNEY COLLECTOR 4- BLOCKAGE SPY LIGHT 5- WORKING SPY LIGHT 6- SUPPORT FOR BRACKETS 7- BAFFLES 8- FIRE PLACE 9- EXCHANGER 10- NOISE/HEAT INSULATOR 11- FAN 12- HEAT INSULATOR 13- CHAMBER CHECKING PEEP- HOLE 14- BURNER SUPPORT PLATE 15- ELECTRONIC BOARDS SUPPORT PLATE 16- TERMINAL BOX WITH FUSE 17- BURNER THERMOSTAT 18- FAN THERMOSTAT 19- RESET THERMOSTAT 20- KEY LOCK 21- SEALING PROTECTION 22- CHAMBER BRACKET SUPPORT 23- INSIDE AIR BAFFLE 24- DOOR FOR CHECKING AND CLEANING 25- FAN BULB 26- LIMIT BULB 27- RESET BULB Pict. 7 15

16 K X HANGING SERIES HOT AIR GENERATORS WIRING DIAGRAM F = Fuse 5x20 T 3.15A MC = Fan engine TM = Maximum thermostat TL = Limit thermostat TF = Fan thermostat MI = Fan inside terminal board LF = Working spy light LB = Blockage spy light MV = Fan terminal board MB = Burner terminal box BR = Blow type burner * OUTSIDE = OPTIONS TO BE INSTALLED BY THE CUSTOMER * IMT = Magneto-thermal switch * TA = Room thermostat Pict. 8 16

17 K X HANGING SERIES HOT AIR GENERATORS WIRING DIAGRAM FOR APPLIANCES SET READY FOR SUMMER VENTILATION BY FAN F = 5x20T 15A Fuse MC = Fan engine TM = Maximum thermostat TL = Limit thermostat TF = Fan thermostat MI = Fan inside terminal board LF = Working spy light LB = Blockage spy light MV = Fan terminal board MB = Burner terminal box BR = Blow type burner * OUTSIDE = OPTIONS TO BE INSTALLED BY THE CUSTOMER *IMT = Magneto-thermal switch *TA = Room thermostat *DV = Summer/winter switch 17 Pict. 9

18 K X Hanging Series Hot Air Generators WIRING DIAGRAM Where REMOTE CONTROL Is Used 19