ECONOAR 3000R SERES AR HANDLNG UNT DRECT FRED nstallation, Operation & Maintenance nstructions STOKVS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL: 020 8783 3050 / 08707 707 747 FAX: 020 8783 3051 / 08707 707 767 E-MAL: info@stokvisboilers.com WEBSTE: www.stokvisboilers.com JULY 1999
... TABLE OF CONTENTS 3000R 1 TECHNCAL DATA...5 1.1 Specification... 5 1.2 Utilities... 6 1.3 Settings (As shipped)... 7 Process and nstrumentation Diagram General Arrangement Wiring Diagram 2 GENERAL DESCRPTON...8 2.1 ntroduction... 8 2.2 Gas Burner Assembly... 8 2.3 Control System... 8 2.3.1 Safety Controls... 8 2.3.2 Temperature Control System... ~... 9 2.3.3 Main Control PaneL... 9 2.3.4 Fuel Gas System... 9 2.3.5 Remote Control Station... 10 3 NSTALLATON...11 3.1 Statutory Requirements... 11 3.2 Reception and Storage of Goods... 11 3.2.1 Reception... 11 3.2.2 Off Loading... 11 3.2.3 Storage... 11 3.3 Limitations of Use... 12 3.4 Location of Air handlers... < 12 3.5 Fresh Air nlet and Ventilation... 13 3.5.1 Fresh Air nlet... 13 3.5.2 Ventilation... 14 3.6 Air Discharge... 14 3.7 Recirculation Air Entry... 14 3.8 Assembly and Positioning of Air handler... 15 3.9 Remote Station... 15 3.10 Pressure Control System... 15 3.11 Visual Check... 15 3.12 Connection of Services... 16 3.12.1 Fuel Gas Supply... 16 3.12.2 Electricity Supply... 16 3.13 Connection to the Main Panel and Remote Station... 17 3.14 Heated Space Temperature Sensor... 17 3.15 Duct Sensor... 17 3.16 Overheat Limit Control Sensor... 17 3.17 Touch Screen Wiring... 17 JULY 1999 SAMPLE Page 1
TABLE OF CONTENTS 3000R 3.18 Alignment... 18 3.18.1 nstallation Of drive Belts... 18 3.18.2 Pulleys... 18 3.18.3 Alignment... 18 3.18.4 Belts... 18 3.18.5 nstallation & Take Up Allowance... 19 4 COMMSSONNG...20 4.1 Pre-start Checks... 20 4.2 Dry Run... 21 4.3 Start Up... 21 4.3.1 Flame Signal Check... 22 4.3.2 Damper Setting Check... 23 4.3.3 Testing the Pressure Control Loop... 25 4.3.4 Handover... 25 5 ADJUSTMENTS...26 5.1 Pilot Adjustment... 26 5.2 Burner High Fire Pressure Adjustment..... 26 5.3 Burner Low Fire Adjustment... 26 5.4 SUMMEROFFWNTER Switch... 27 5.5 RESET Button... 27 5.6 Recirculation Override... 27 6 OPERATNG NSTRUCTONS...28 6.1 Air handler Start-up... 28 6.2 Air handler Shut-down... 28 6.2.1 Shutdown For Short Periods... 28 6.2.2 Shutdown For Prolonged Periods... 28 6.3 General nstructions... 0... 0... 29 6.3.1 Site Clearance Adjacent to Air handler... 29 6.3.2 Air Supply to Air handler... 29 6.3.3 Air Filters... 29 6.3.4 Service... 29 6.3.5 Spare Parts... 29 6.3.6 Gas Leaks... 29 7 FAULT FNDNG...30 7.1 POWER ON light is unlit... 30 7.2 AR FAN ON light is unlit... 31 7.3 DAMPER CRCUT PROVED light is unlit... 32 7.4 LOCKOUT light is illuminated... 32 7.5 AR FAN ON and DAMPER CRCUT PROVED lights illuminated... 33 JULY 1999 SAMPLE Page 2
TABLE OF CONTENTS 3000R B SERVCNG...34 8.1 solation... 34 8.1.1 Fuel Gas solation... 34 8.1.2 Electrical solation... 34 8.2 Routine Maintenance... 35 8.3 Annual Service Checks... 35 8.4 Removal Procedure For Replaceable Components... 36 8.4.1 Burner... 36 8.4.2 Flame Detector... 36 8.4.3 gniter Spark Plug... 36 8.4.4 gniter Spark Transformer... 37 8.4.5 Combustion Air Pressure Switch (DPS)... 37 8.4.6 Air handler Overheat Limit ControL... 37 8.4.7 Recirculation/Fresh Air Dampers & Motor... 37 8.4.8 Damper Microswitch... 38 8.4.9 Air Fan and Motor... 38 8.4.10 Fuel Gas Multi-functional Control - Small Units... 39 8.4.11 Governor and Block Valves... 39 8.4.12 Fuel Gas Flow Control Valve... 39 8.4.13 Workspace Pressure Controller... 40 8.4.14 Pilot Gas Governor and Block Valve... 40 8.4.15 Belt Tensioning Procedure... 41 8.5 Main Panel Controls... 43 8.5.1 Landis & Gyr LFL 1.335 Automatic Sequence Controller... 43 8.5.2 Controls Circuit (24 Volt) Transformer... 43 8.5.3 Controls Relays, R1, R2 &R3... 43 8.5.4 6A MCB... 43 8.5.5 Thermal Overload... 43 8.5.6 Main Contactor... 44 8.5.7 Motor Fuse... 44 8.6 Remote Control Station... 44 9 RECOMMENDED SPARES...45 JULY 1999 SAMPLE Page 3
TABLE OF CONTENTS 3000R APPENDX 1 SOUNDNESS TESTNG THE FUEL GAS LNE... 46 A1.1 Testing the Upstream Pipework and Burner Controls... 46 A1.2 Testing the Downstream Burner Valve... 47 A1.3 Testing the Downstream Burner Pipework... 47 A1.4 Testing the Downstream Pilot Pipework... 47 A1.5 Testing the Burner Connections... 48 APPENDX 2 START SEQUENCE... 49 APPENDX 3 SERVCE CHECK SHEET... 54 APPENDX 4 TEMPERATURE CONTROLLER... 55 A4.1 Time Out Screen... 55 M.2 Status Screen... 56 A4.3 Changing Settings... 57 A4,4 Entering the Security Code... 57 A4.5 Changing or Setting a Time Schedule... 59 A4.6 Changing Set Values... 61 A4.7 Commissioning and Servicing Burner Checks... 62 A4.8 GMT<>BST Changeover (Daylight Saving)... 62 JULY 1999 SAMPLE Page 4
1 TECHNCAL DATA 3000R 1.1 SPECFCATON 30**R 99 CE 0087 G20 87AQ378 N/A 17 10 5 415V, 50Hz, 3ph, 4 Wire A E kg JULY 1999 SAMPLE Page 5
1 TECHNCAL DATA 3000R 1.2 UTLTES AR HANDLER UTLTES FUEL MAXMUM FUEL SUPPL Y PRESSURE MNMUM FUEL SUPPLY PRESSURE ELECTRC SUPPL Y TO CONTROL PANEL WTH NEUTRAL WRE SUPPL Y RATNG MOTOR FUSES NATURAL GAS 25 mbar 15 mbar 415V, 50Hz, 3ph, 4 Wire Amps Notes: Air handler models 3018R to 3040R inclusive of STOKVS ECONO AR 3000R Series air handler, have been certificated by British Gas Pic for use on Natural Gas only. t does not cover the use of distribution ducting, filters and high level or external installations. The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample. Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 3.3. JULY 1999 SAMPLE Page 6
1 TECHNCAL DATA 3000R 1.3 SETTNGS (AS SHPPED) AR PRESSURE SWTCH AR HANDLER SETTNGS (AS SHPPED) mbar OVERHEAT LMT CONTROL 65 C PLOT BURNER GAS PRESSURE MAN BURNER GAS PRESSURES MAXMUM AT RECRCULATON CONDTON OVERLOAD FAN SPEED DFFERENTAL AR PRESSURE ACROSS PROFLE PLATE GAS CONNECTON SZE TEMPERATURE CONTROLLER MAXMUM MNMUM MAXMUM MNMUM 10.0 mbar 5.0 mbar 1.0 mbar mbar Amps rpm 1.6 mbar 1.4 mbar "BSP ACCESS CODE 4321 TEMPERATURE SETPONT (Code 00) 19 C SAMPLE NTERVAL (Code 01) 2 sec DSCHARGE LOW LMT (Code 02) 18 C DSCHARGE HGH LMT (Code 03) 36 C Note: For air handler dimensions, please refer to the General Arrangement Drawing. JULY 1999 SAMPLE Page 7
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2 GENERAL DESCRPTON 3000R 2.1 NTRODUCTON The STOKVS ECONO AR 3000R Series air handler is a direct fired unit designed to give clean, healthy environmental conditions and constant even temperature within the heated space. The main air handler assembly houses the circulating air fan, the gas burner, the fuel gas line and all necessary safety controls. The burner management system and space temperature controller are located in the main control panel mounted on or adjacent to the side of the air handler. A second control station, supplied loose for mounting remote from the air handler within the heated space or other convenient location, houses indicating lights, the control touch screen* and auxiliary operational switches. A sight glass is fitted on the air handler casing to view the burner during operation. * For multi unit networked applications, the touch screen is excluded. 2.2 GAS BURNER ASSEMBLY The STOKVS ECONO AR 3000R Series air handler incorporates the Maxon NP- burner. This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements. The burner assembly is built up from modular components to give the required heat duty. Each burner assembly is fitted with an integral pilot, spark igniter and UV detector. The flame detector is used for scanning both the pilot and main 'Harne. Note that the pilot burner operates in interrupted mode. The burner module fitted is identified in the Technical Data Section of this manual, and on the Valve and nstrument list. 2.3 CONTROL SYSTEM The controls fitted on the air handler are detailed on the Process & nstrumentation Diagram in the Technical Data Section of this manual. 2.3.1 SAFETY CONTROLS The safety interlocks on the STOKVS ECONO AR 3000R Series air handler are: 1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLC) 4 Fresh Air Damper Open Microswitch (CS1) Failure of either the combustion air switch or flame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted. The air handler discharge overheat limit control is a manual reset switch. After a failure the switch will have to be RESET before a re-light can be attempted. JULY 1999 SAMPLE Page 8
2 GENERAL DESCRPTON 3000R 2.3.2 TEMPERATURE CONTROL SYSTEM The STOKVS ECONO A R 3000R Series air handler is fitted with a full three-term modulating temperature control system as standard. The space temperature is sensed by a heated space detector (TR), which inputs to the panel mounted temperature controller (Te). This achieves control by modulation of the fuel gas flow control valve (MV5). The temperature controller additionally limits the air handler discharge air terrlperature, measured by the discharge temperature detector (TO), to pre-set high and low limits. 2.3.3 MAN CONTROL PANEL The control panel houses the combustion/circulation air fan starter, the burner management system and the heated space temperature controller. On larger units, a separate starter panel may be supplied. The panel door is fitted with an interlocked isolator, POWER ON, and LOCKOUT lights and the burner management RESET button. The panel is mounted on or adjacent to the air handler. 2.3.4 FUEL GAS SYSTEM The PLOT LNE comprises: 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings Note: Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve. The MAN GAS LNE comprises: 1 Gas isolation valve (MV 1 ) 2 Pressure governor (MV2) 3 Double block safety shut-off system (MV3/4) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings Note: Four pressure test points are fitted on the main gas line; on the supply, the inlet and discharge of the second block valve and downstream of the flow control valve. Note: On small air handlers items 2 and 3 are combined in one multi-functional control. All items above are detailed on the Process & nstrumentation Diagram in Section 1 of this manual. JULY 1999 SAMPLE Page 9
2 GENERAL DESCRPTON 3000R 2.3.5 REMOTE CONTROL STATON The STOKVS ECONO AR 3000R series air handler is also supplied with a remote control station, which houses the air handler operating controls, indicating status and the workspace temperature detector if the control station is located in the heated space. JULY 1999 SAMPLE Page 10
3 NSTALLATON 3000R 3.1 STATUTORY REQUREMENTS n accordance with the Gas Safety (nstallation and Use) Regulations 1998, installation of this STOKVS ECONO AR 3000R Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974. The installation of this air handler must comply with: BS6230-1991, nstallation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW. The EE Regulations for Electrical nstallations Gas Safety (nstallation and Use) Regulations 1998 Health and Safety at Work Act 1974 Building Regulations 1986 Building Standards (Scotland Only) The nstitution of Gas Engineers Codes of Practice: GE/UP/1 Soundness Testing Procedures for ndustrial and Commercial Gas nstal1ations. GE/UP/2 Gas nstallation Pipework, Boosters and Compressors on ndustrial and Commercial Premises. GE/UP/4 Commissioning Of Gas Fired Plant On ndustrial and Commercial Premises 3.2 RECEPTON AND STORAGE OF GOODS 3.2.1 RECEPTON On receipt of the shipment check that the shipment is complete against the Delivery Advice Note. Check for mechanical damage sustained during transit before off-loading the goods. nform the carrier of any such damage. 3.2.2 OFFLOADNG Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift. Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame. 3.2.3 STORAGE Air handlers must be stored in a dry environment. The remote control station must be removed from the shipment and stored indoors in a dry environment. Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete. Any filter elements should be stored in a dry environment. JULY 1999 SAMPLE Page 11
3 NSTALLATON 3000R 3.3 LMTATONS OF USE The STOKVS ECONO AR 3000R Series air handler must not be installed in the following locations: n hazardous areas n areas where flammable vapours can be present in excess of their threshold limit values, as defined in 8S5925. n accordance with 8S6230, Clause 5.1.3, where there are any flued appliances in the heated area, and where air is supplied mechanically and there is mechanical extraction, the design extract rate must be 5% to 10% less than the design inlet rate so that the room will not be at a lower pressure than the outside air. f the air handler is the only source of mechanically supplied air, the extract rate must not exceed 95% of the nominal air flow specified in Section 1.1 of this manual. Note: f it proposed to install the STOKVS ECONO AR 3000R Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present, the installation must first be approved by a R.S. STOVS Ltd. Engineer. 3.4 LOCATON OF AR HANDLERS The air handler should normally be installed in the location recommended by the R.S. STOKVS Ltd. specifying engineer. Check the proposed location for level and load bearing strength. Ensure that there is adequate clearance, as detailed on the air handler GA in Section 1 this manual, around the unit for access for maintenance purposes. f the air handler is to be installed above floor level, a suitably designed service platform should be provided. Such a platform must have 100mm minimum raised edges around the perimeter. f this is not possible, all air handler access panels must be fitted with hinged restraints. This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation. JULY 1999 SAMPLE Page 12
3 NSTALLATON 3000R 3.5 FRESH AR NLET AND VENTLATON 3.5.1 FRESH AR NLET The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building. Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts. Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners. The fresh air inlet should be sized for an air velocity of 3m/s. The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual. Where the fresh air inlet is made in a load bearing wall, e.g. a brick wall, guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening. A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall. Additionally the weather hood should have negligible resistance to the airflow, maximum 0.1 mbar at the design air 'How rate. Do not install the STOKVS ECONO AR 3000R Series air handler where long lengths of duct or bends of an angle greater than 30 are necessary to lead to the air handler from the fresh air opening. f ducting is unavoidable, ensure that the resulting pressure drop is negligible, i.e. less than 0.1 mbar for ductless air handlers, and has been accounted for in the original design for ducted air handlers, as detailed in the speci'fication section of this manual, Section 1.1. Note: f the air intake is located in an area of unrestricted access, warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake. JULY 1999 SAMPLE Page 13
3 NSTALLATON 3000R 3.5.2 VENTLATON Where the air air handler is in its own plant room or compartment, this shall be ventilated with openings communicating directly with the outside air to ventilate the room. The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded. They shall have a total minimum free area as follows: Low Level (inlet): 320cm 2 + 2.7cm 2 per kilowatt in excess of 60kW total rated input. High Level (outlet): 160cm 2 + 1.34cm 2 per kilowatt in excess of 60kW total rated input. The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening. Grilles shall be designed to minimise high velocity air streams in the plant room. For exposed, Le. free standing plant rooms, ventilation openings shall be provided on at least two sides, and preferably on all four sides. Where mechanical ventilation is used, it shall be by mechanical inlet and either natural or mechanical extraction. Systems of ventilation employing mechanical extraction and natural air inlet shall not be used. The minimum flow rates of air supplied shall be not less than 0.6 m 3 ts per megawatt of rated heat input. 3.6 AR DSCHARGE The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres. The air should not discharge directly onto any obstructions, and direct discharge on to working personnel should be avoided. f the air discharge is located in an area of unrestricted access, warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge. Generally it is not necessary to fit distribution ducting to the discharge of the air handler. f ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification, as detailed in Section 1 of this manual. 3.7 RECRCULATON AR ENTRY The recirculation air entry is fixed by the location of the air discharge and the air handler orientation and is shown on the General Arrangement Drawing. Ensure that the recirculation air path is not restricted and cannot be blocked by temporary storage. f the recirculation air return duct is located in an area of unrestricted access warning notices preventing the blockage of this duct by temporary stacking should be displayed adjacent to it. JULY 1999 SAMPLE Page 14
3 NSTALLATON 3000R 3.8 ASSEMBLY AND POSTONNG OF AR HANDLER Unless specified at the time of order air handlers will be shipped in sections. Discharge heads, grilles, attenuators, duct connecting sections, filters, rain-hoods etc., will be supplied loose for site fitting to the air handler. Horizontal air handlers must be supported on their steel angle support base. When the air handler is located check for level and adjust as necessary. Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports. This must be specified at the time of order. Do not suspend the air handler from the lifting eyes. 3.9 REMOTE STATON The STOKVS ECONO AR 3000R Series air handler is supplied with a remote control station. This should be mounted in a position convenient to the end user. f possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat. 3.10 PRESSURE CONTROL SYSTEM The STOKVS ECONO AR 3000R air handler is supplied with a pressure control system which controls the positive pressure inside the workspace. t is located adjacent to the air handler control panel and is clearly marked NULL SWTCH. The pressure sampling points on this controller must be piped to their sensing points as follows. Using the 5/16" copper tubing provided: 1 The high pressure tapping should be piped a minimum of 3 metres from the air handler to a location within the building which is not affected by the discharge or recirculation air 'Hows. 2 The low pressure tapping should be piped outside the building and terminated a minimum of 3 metres from the air handler. Locate this tapping away from the corners of the building and ensure that it cannot be blocked or damaged. Long radius bends must be used to avoid kinks in the pipe. The open end must be turned downwards to avoid the ingress of foreign substances which could cause a blockage. 3.11 VSUAL CHECK After completion of installation re-check the air handler for signs of damage. Report any instance to R.S. STOKVS Ltd. JULY 1999 SAMPLE Page 15
3 NSTALLATON 3000R 3.12 CONNECTON OF SERVCES The air handler requires the connection of fuel gas and electricity. 3.12.1 FUEL GAS SUPPLY The STOKVS ECONO AR 3000R Series air handler has been designed for use on Natural Gas. Analtemative version is available for LPG. The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual. Check the gas type is correct and that the supply pressure is within the range marked on the specification. The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply. Connect the fuel gas supply to the inlet manual valve on the air handler gas train. The connection size is detailed in Section 1 of this manual. A further isolation valve and union should be fitted immediately adjacent to the appliance which, when the valve is closed, allows the complete burner and control assembly to be disconnected for maintenance or repair. New gas pipework should be installed to The nstitution of Gas Engineers Codes of Practice: GE/UP/1 Soundness Testing Procedures for ndustrial and Commercial Gas nstallations. GE/UP/2 Gas nstallation Pipework, Boosters and Compressors on ndustrial and Commercial Premises. GE/UP/4 Commissioning Of Gas Fired Plant On ndustrial and Commercial Premises 3.12.2 ELECTRCTY SUPPLY All external wiring shall be carried out and checked by a competent person. All components shall be checked for suitability for voltage range and frequency. Means for electric isolation, having a contact separation of at least 3mm in all poles, must be provided adjacent to the air handler. The electrical supply to the appliance shall incorporate suitable means of excess current protection. The STOKVS ECONO AR 3000R Series air handler requires a 3 phase 4 wire supply, which should be connected to the main control panel. Check the air handler data badge for the correct electrical supply. The maximum supply requirement is Specified in Section 1 of this manual. Note that the 240 Volt air handler control circuit is taken from the 'U' phase to Neutral. Connection should be made as shown on the wiring diagram shipped inside this panel. The air handler must be earthed in accordance with BS5986 and CP1013. Check all terminal strip terminations for wires which have become loose during shipment. JULY 1999 SAMPLE Page 16
3 NSTALLATON 3000R 3.13 CONNECTON TO THE MAN PANEL AND REMOTE STATON nterconnecting wiring to the main panel and remote station should be made with a minimum specification of 0.75 mm 2 300 Volt cable. Check that no wires on the terminal strip have become loose during shipment. The remote panel should be mounted at a height of approx. 1.8m. f possible, it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat. 80th panel and remote station must be earthed in accordance with 8S5986 and CP1013. 3.14 HEATED SPACE TEMPERATURE SENSOR The space temperature sensor located on the remote panej should be connected with screened cable or twin low voltage signal cable, run in its own separate conduit. t should be mounted on the remote panel or adjacent to the outlet at a height of approx. 1.8m. f possible, it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat. 3.15 DUCT SENSOR The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit. t should be mounted in the air handler discharge as close as possible to the discharge into the heated space. 3.16 OVERHEAT LMT CONTROL SENSOR The overheat limit control sensor should be connected with twin core cable. t should be mounted in the air handler discharge within 1 metre of the air handler outlet connection. 3.17 TOUCH SCREEN WRNG The touch screen, located on the front of the remote station, requires two separate twisted pairs of 0.5mm 2 screened cable, run in a separate conduit. f the distance between the main and remote stations is greater that 1 km, please contact R.S. STOKVS Ltd. for advice. JULY 1999 SAMPLE Page 17
3 NSTALLATON 3000R 3.18 ALGNMENT 3.18.1 NSTALLATON OF DRVE BELTS On 80 &89 3000R range of air handlers, it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit. 3.18.2 PULLEYS Before assembling the drive, check the pulley grooves are free from scores or sharp edges, and all dimensions conform to the relevant standard. The Taper Lock bush is your starting point when it comes to assembly and installation. Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely. 3.18.3 ALGNMENT Good alignment of pulleys prior to belt installation is important to avoid belt 'Hank wear. The diagram below shows correct installation of pulleys. NTERNAl BEARNG ran PuU. Y MOTOR MOUNTNG BOLTS MOTOR ADJUSTMENT BOLTS 3.18.4 BELTS When the pulleys have been correctly positioned on the shafts, the belts can be installed to complete the drive. The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force. Under no circumstances must belts be prised into the grooves. Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves. The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting. The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch. JULY 1999 SAMPLE Page 18
3 NSTALLATON 3000R 3.18.5 NSTALLATON AND TAKE UP ALLOWANCE Belt Pitch Length (mm) 410 to 530 540 to 840 850 to 1160 nstajlation Allowance. SPZ SPA SPB SPC Take-Up (mm) 5 10 15 1170 to 1500 20 1510 to 1830 20 25 1840 to 2170 30 2180 to 2830 25 40 2840 to 3500 30 50 3520 to 4160 50 60 4170 to 5140 70 5220 to 6150 85 6180 to 7500 105 7600 to 8500 125 8880 to 10170 145 10600 to 12500 175 JULY 1999 SAMPLE Page 19
4 COMMSSONNG 3000R A R.S. STOKVS Ltd. approved engineer must commission this appliance. 4.1 PRESTART CHECKS 1 Switch the SUMMEROFFWNTER switch on the remote station to OFF. 2 Check the correct electric supply is available to the air handler and the appliance isolator installed. 3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed. Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position. 4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual. 5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3). 6 Close the air handler access door. 7 Close and lock the main air handler control panel. 8 Switch the main panel isolator to position 1. Check the POWER ON light illuminates. 9 Check and set the timed ON/OFF periods in the lac Controller located on the remote panel. Ensure that the unit is set to be on during testing. Refer to Appendix 4 for the lac setting procedure. 10 Close and lock the remote panel. 11 Switch the SUMMEROFFWNTER switch on the remote station to SUMMER to start the air fan. Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops. The fan rotation can be observed through the fan section access door or through the air handler access door. Only do this during the fan run-down period. Ensure the door is securely fastened after completion. Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support. f the rotation is incorrect, two phases should be interchanged, as dictated by the Engineer responsible for the site electrical system. 12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS). This pressure should be between 1.4 and 1.6 mbar. f the air differential pressure measured above is not within the operating range, check inlet and outlet ductwork as appropriate, and any filters fitted. f the pressure differential is still not within limits, isolate the air handler and report to R.S. STOKVS Ltd. before proceeding. 13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch. Check the break point on the switch is 1 mbar (falling). Note: The switch is set and sealed before fitting. The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch. f, on checking, the switch is not operating correctly, do not tamper with it; return it to R.S. STOKVS Ltd. for replacement. JULY 1999 SAMPLE Page 20
4 COMMSSONNG 3000R 4.2 DRY RUN With all the manual gas isolation valves still in the OFF position, switch the SUMMEROFFWNTER switch to WNTER. Approximately 30-45 seconds later, the DAMPER CRCUT PROVED light on the remote control station illuminates. Check that the air handler attempts to start and goes to LOCKOUT. Note: f the DAMPER CRCUT PROVED light does not illuminate, refer to the fault finding section of this manual. 4.3 START UP 1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS). 2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3). Leave the main burner isolation valve (MV6) closed. Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station. The air handler pilot wil1light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed. During the short period that the pilot is in operation, check the pilot gas pressure on the manometer. t should be 10 mbar and the pilot flame approximately 1 00-150mm in length. covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler. Adjust as necessary - refer to Section 5.1 this manual. Check the flame signal - refer to Section 4.3.1. 3 Open the main burner isolation valve (MV6). RESET the air handler which should now light to main burner stage. When alight, close the main burner isolation valve to shut down the gas flow to the burner. Check that the unit goes to LOCKOUT. 4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point. as described in Appendix 4 of this manual. Check the flame is continuous across the width of the burner and has a flame length of approx. 50-65mm from the burner rail when viewed through the sight glass on the access side of the air handler. Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch, i.e. on the rear of the pressure switch. This pressure is specified in Section 1 of this manual. Adjust as necessary refer to Section 5.3 of this manual. Check the flame signal - refer to Section 4.3.1. Where possible, check the actual gas flow rate by meter reading with all other appliances turned off. 5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55 C, as described in Appendix 4 of this manual. Check the flame is continuous across the burner rail and has a flame length of approximately 250-350mm from the burner rail. Check the burner pressure across pressure test point 0 and the downstream (low) pressure test point on the air pressure switch. This pressure is specified in Section 1 of this manual. Adjust as necessary - refer to Section 5.2 of this manual. Check the maximum air handler discharge temperature. Check the flame signal refer to Section 4.3.1. Where possible check the actual gas flow rate by meter reading with all other appliances turned off. 6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65 C, as described in Appendix 4 of this manual. Monitor the discharge temperature on the temperature controller. Check that the overheat control operates as the set temperature is passed. Check that the control must be manually reset by pressing the green reset button on the front of the switch. Return the temperature controller to its original settings. n the event that the ambient temperature is too low for this simple procedure to work. the instrument will have to be bench tested using a Temperature 8ath. Remove and replace the control, as Section 8.4 of this manual, for bench-testing. JULY 1999 SAMPLE Page 21
4 COMMSSONNG 3000R 4.3 1 FLAME SGNAL CHECK 1 The STOKVS ECONO AR 3000R Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal. Refer to the Electrical Schematic and connect a 0-1 ma ammeter to the two test points with standard 2.3 mm test plugs, with the positive lead on the detector side. Disconnect the terminal link to obtain the signal reading. A minimum signal of 70 microamps is required; typical signals are in the 250-400 microamp range on both pilot and main name. After completion, replace the terminal link and remove the test jacks. 2 Drive the burner to high fire as previously described. Measure the carbon dioxide content of the discharge air stream. This figure must not exceed 2800 ppm. f the discharge exceeds this limit, isolate the air handler and report to R.S. STOKVS Ltd. before proceeding. 3 Stop and start the air handler a few times to check for reliability, using the Operating nstructions, (Section 6). JULY 1999 SAMPLE Page 22
4 COMMSSONNG 3000R 4.3.2 DAMPER SETTNG CHECK The maximum heat input (recirculation condition) must NOT be exceeded unless the fresh air damper is fully open. To achieve this, the STOKVS ECONO AR 3000R air handler is designed to override the building pressure control system when the fuel gas input, required by the temperature control circuit, exceeds the pre-set value for maximum heat input (recirculation condition). This limit is specified in Section 1 of this manual. This prevents the air handler discharge contaminants exceeding the code requirements under any circumstances. The fuel gas control valve (MV5) is fitted with a third microswitch, marked N, which energises the pressure control loop at gas flows below the pre-set value at which the fresh air damper must be fully open. At the pre-set value the switch changes over, removing power from the pressure control loop (which disables the OPEN/CLOSE switch on the remote control panel and also the workspace pressure controller), and puts a permanent power supply to the damper motor drive-close terrriinal, which drives the fresh air damper open. 1 To check this setting, switch the Auto/Manual switch on the Remote panel to MANUAL and fit a manometer to pressure test point D on the main gas line and the low pressure tapping, i.e. on the rear of pressure switch, on the air pressure switch (DPS), as shown in Figure 2. Start the air handler and, when the main burner is lit, drive the burner to low fire by adjusting the temperature control1er set-point and low limit to O C, as described in Appendix 4 of this manual. 2 With a voltmeter, check the voltage across the OV terminal on the step down transformer and the relevant terminal. This circuit is 24V, and a reading of this value signifies the relevant terminal energised. Check that the recirculation damper position can be adjusted on the manual Open/Close switch on the Remote Panel. Leave the damper in a partially open position. 3 Drive the burner to high fire, by adjusting the temperature controller set-point and high limit to 55 C, as described in Appendix 4 of this manual. Monitor as above; when the gas pressure on the manometer reaches the maximum at recirculation condition check that the recirculation damper now drives to the fully closed position (full fresh air). Check that the manual Open/Close switch on the Remote Panel has no effect. f necessary, the switching point may be adjusted as described in Section 5.6 of this manual. 4 Set the damper Auto/Manual Switch on the Remote Panel to Manual and, using the Open/Close switch, drive the fresh air damper to the full open condition by selecting OPEN on the Open/Close selector switch. 5 Drive the burner to high fire as previously described. Measure the carbon dioxide content of the discharge air stream. This figure must not exceed 2800ppm. f the discharge exceeds this limit, isolate the air handler and report to R.S. STOKVS before proceeding. 6 Set the damper Auto/Manual Switch on the Remote panel to Manual and, using the Open/Close switch, drive the fresh air damper to the full closed condition. 7 Adjust the controller set point to inch the control valve to its maximum firing rate, to stop the fuel gas valve opening beyond the maximum heat input (recirculation condition). When set correctly, the burner will be firing at the maximum heat input (recirculation condition), with the fresh air damper fully closed and the recirculation air damper fully open. Any increase in the high limit temperature will cause the damper override circuit to function, driving the dampers to the full fresh air condition. JULY 1999 SAMPLE Page 23
4 COMMSSONNG 3000R 4.3.2 DAMPER SETTNG CHECK (cont.) 8 When the burner is functioning as above, measure the carbon dioxide concentration in the air handler discharge and in the recirculation air stream immediately before the air handler recirculation air entry. The air handler discharge carbon dioxide must not exceed 2800 ppm. f the discharge exceeds this limit, isolate the air handler and report to R.S. STOKVS before proceeding. 9 Return the temperature controller to its original settings and switch the damper Auto/Manual switch to Auto. JULY 1999 SAMPLE Page 24
4 COMMSSONNG 3000R 4.3.3 TESTNG THE PRESSURE CONTROL LOOP 1 With the air handler in service and the damper Auto/Manual switch on the Remote Panel in Auto, remove the impulse lines from the building pressure controller mounted on the air handler casing. f necessary, ensure the heat input is less than the maximum recirculation condition heat input as described in clause 7 above. nject a test signal of 1 mbar on the high pressure tapping and check that the fresh air damper closes. Similarly, inject a test signal of 1 mbar on the low pressure tapping and check that the fresh air damper opens. 2 Reinstate the impulse lines. Note: The pressure controller is factory set and sealed. There is no requirement to adjust the setpoint. 3 Stop and start the air handler a few times to check for reliability, using the Operating nstructions, (Section 6). Measure and record the building pressure after approximately 30 minutes running with the air handler fresh air damper in the fully open position. Note: For an installation with more than one air handler unit, this check should be made with all the air handlers in operation. 4 f the user will permit it, check that the pressure control responds satisfactorily in service by opening and/or closing the largest openings, e.g. the loading doors of the workspace. 4.3.4 HANDOVER Complete the air handler Service Check Sheet supplied at the back of this manual. The self-copy sheet must be returned to R.S. STOKVS for checking. nstruct the User in efficient use and care of the unit, start-up and shutdown (including emergency shutdown) and recommended service interval. Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets. Hand all instructions, as applicable, to the User/Owner for safe keeping. JULY 1999 SAMPLE Page 25
5 ADJUSTMENTS 3000R f adjustments to the air handler settings are required they should be made by a R.S. STOKVS Ltd. approved engineer. The normal value for all control settings is specified in Section 1 of this manual. 5.1 PLOT ADJUSTMENT The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor. Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length; anti-clockwise decreases the pressure and the flame length. 5.2 BURNER HGH FRE PRESSURE ADJUSTMENT At high fire, alter the spring cornpression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate; clockwise to increase the burner pressure, anti-clockwise to decrease burner pressure. f the pressure does not increase on adjusting the spring, the supply is inadequate. Note: On small air handlers fitted with a multi-functional control, the pressure adjusting screw is located under a swing cap on the first block valve. 5.3 BURNER LOW FRE ADJUSTMENT The main burner low fire is adjusted on the flow control valve, MV5 (Process & nstrumentation Diagram). Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam, marked N. Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05 C, as described in Appendix 4 of this manual. Tum the Terminal Screwdriver clockwise to decrease the low fire gas flow; anti-clockwise to increase the flow. Check the heat input and flame signal at the new position are satisfactory and return the temperature controller to its normal settings. Replace the control valve cover. JULY 1999 SAMPLE Page 26
5 ADJUSTMENTS 3000R 5.4 SUMMEROFFWNTER SWTCH n the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods. This position is manually selected and must be manually de-selected. Whenever the switch is in this position, the fan is operating. n the OFF position the air handler is shutdown and will not operate. This overrides any frost protection fitted. t is suitable for air handler shutdown for short periods such as holidays. The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WNTER position. n the WNTER position the air handler operates off the programme memory to provide heating. 5.5 RESET BUTTON Visual indication of air handler lockout is provided. n the event of lockout occurring, the air handler can be reset by depressing the RESET button. This parallels the RESET button on the air handler main control panel. f, after 4 attempts to reset the air handler, the lockout indicator still illuminates, then a Service Engineer should be called to investigate the problem. 5.6 ADJUSTNG THE RECRCULATON OVERRDE The recirculation override is adjusted on the flow control valve, MV5. Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the cam, marked Nili. This is the bottom cam of three. The cam switch operates as the valve travels and does not stop the valve movement. Thus the setting can only be adjusted at each end of the travel and the switching point checked as the valve operates. Alternately, drive the burner to high fire and to low fire by adjusting the temperature controller as described in Appendix 4. Check the change-over point with a voltmeter and adjust the cam setting at the end of the travel as necessary. Turn the Terminal Screwdriver clockwise to decrease the switching point and hence the burner pressure; anticlockwise to increase. Check the new position is satisfactory as detailed in Section 4.3 of this manual and return the controller to its normal settings. Replace the control valve cover. JULY 1999 SAMPLE Page 27
6 OPERATNG NSTRUCTONS 3000R 6.1 AR HANDLER START-UP 1 Open all manual gas valves both on the appliance and on the supply to the appliance. Switch on the Electric Supply to the appliance. 2 On the main air handler panel: Switch the panel isolator to the 1 position Check POWER ON light 3 On the remote control station: For Heating: Switch the SUMMEROFFWNTER switch to WNTER. The air handler will now start automatically in response to the time settings. n the event of LOCKOUT: Press the RESET button and the cycle of operations will be repeated. f the air handler goes to LOCKOUTfour times in succession call for a Service Engineer. For Unheated Ventilation: Switch the SUMMEROFFWNTER switch to SUMMER. Note: This prevents the burner firing, giving a controlled supply of ventilation air to the heated space, as long as the switch is in this position. The air handler will now start automatically in response to the timeclock demand. To turn the fan off return the switch to the centre OFF position. n the event of LOCKOUT: Press the RESET button and the cycle of operations will be repeated. f the air handler goes to LOCKOUTfour times in succession call for a Service Engineer. 6.2 AR HANDLER SHUT-DOWN 6.2.1 SHUTDOWN FOR SHORT PERODS Switch the SUMMEROFFWNTER switch on the remote station to OFF. 6.2.2 SHUTDOWN FOR PROLONGED PERODS Switch the main panel isolator to the "0" position and close all manual gas valves both on and leading to the appliance. Note: Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown. JULY 1999 SAMPLE Page 28
6 OPERATNG NSTRUCTONS 3000R 6.3 GENERAL NSTRUCTONS 6.3.1 STE CLEARANCE ADJACENT TO AR HANDLER Attention should be paid to keeping the area around the air handler tidy. No rubbish should be allowed to accumulate in the vicinity of the air handler, and storage of goods etc., should not be permitted within two metres of the air handler. Failure to comply could result in reduced airflow to the air handler, causing inefficient running and potential overheat condition. 6.3.2 AR SUPPLY TO AR HANDLER Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear. 6.3.3 AR FLTERS Similarly, attention should be paid to cleaning or replacing the filters to the air handler, if fitted. Your installer should advise you on the frequency with which this would be required to be completed. 6.3.4 SERVCE For continued safe and efficient operation of this air handler, it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 8.2 of this manual. Users are advised to enter into a Service Agreement with R.S. STOKVS Ltd. 6.3.5 SPARE PARTS t is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed. This is particularly important where the air handler forms an essential part of any process plant, and its being out of operation may cause problems by, for example, frost damage or condensation by super-cooling. A list of Recommended Spares will be found in Section 9 of this manual. 6.3.6 GAS LEAKS f a smell of gas is detected around the area of the appliance. Switch off all manual gas valves and contact your service engineer or the local gas undertaking. NEVER LOOK FOR GAS LEAKS WTH A LGHTED MATCH OR NAKED FLAME JULY 1999 SAMPLE Page 29
7 FAULT FNDNG 3000R The main control panel incorporates two lights to help in fault finding: POWER ON LOCKOUT The remote station also has four lights: AR FAN ON DAMPER CRCUT PROVED BURNER ON LOCKOUT This section gives the possible causes of failure associated with each check light. The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below. Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual. The notes are given for each light; before consulting the notes check for bulb failure. 7.1 POWER ON LGHT S UNLT Check: 1 Main control panel isolator is in the 1 position. 2 3 Main Panel SA MCB has not tripped, if a trip has occurred, the switch will be at the OFF position. Reset and test system as required. Also check if the mains electrical supply is isolated. f so, FND OUT WHY before taking any action. JULY 1999 SAMPLE Page 30
7 FAULT FNDNG 3000R 7.2 AR FAN ON LGHT S UNLT Check: 1 SUMMEROFFWNTER switch is not in Position OFF 2 Timeperiod is not set to off. 3 Air handler is not at LOCKOUT. 4 Recheck both AR FAN ON and LOCKOUT bulbs. Two fault indications are possible: 1 THE FAN S NOT OPERA1"NG f the fan should have started, but is not operating: Check 1 Overload for tripped conditions. Reset the overload and monitor the next start-up. 2 Motor Fuses ~2 &3 for failure. 4 Contactor CC1 for failure. 5 Air Pressure Switch (DPS) is failed in the N 0 Position. Replace the faulty component as described in Section 8. 2 THE FAN S OPERATNG This indicates that the air pressure switch (DPS) has failed to change over. Measure the profile plate differential pressure as described in Section 4.1.13. f the pressure is correct, the air pressure switch is faulty. Check the switch as in 4.1.14. f the pressure is not correct: Check 1 Correct fan belt tension 2 Correct fan rotation 3 The air handler air inlets and discharge are not blocked 4 Correct fitting on filters 5 The air differential pressure switch impulse lines are not blocked or leaking JULY 1999 SAMPLE Page 31
7 FAULT FNDNG 3000R 7.3 DAMPER CRCUT PROVED LGHT S UNLT This light illuminates approximately 20 seconds after the AR FAN ON light illuminates. Failure to light indicates that the damper control circuit has failed to self-check. 1 Switch the air handler off on the SUMMEROFFWNTER switch. Check that the Fresh Air Damper drives to the fully closed position and the Return Air Damper to the fully open position. f not: Check 1 Fuse F5 2 24Volt Transformer ~ayr1 4 Damper Motor 5 Auxiliary switch in flow control valve MV5 2 f the damper drives to the full fresh air position: Check 1 Microswitch CS 1 2 Relay R1 3 Relay R2 7.4 LOCKOUT LGHT S LLUMNATED This light indicates a failure in the burner ignition and flame supervision system. 1 RESET the unit and follow the progress of the start sequence. The full cycle may take two minutes. The start of the burner ignition sequence is indicated by the DAMPER CRCUT PROVED light on the main panel energising. 2 LOCKOUT after 35-40 seconds indicates an ignition failure. RESET the system and observe the pilot and ignition spark during the start-up attempt. 3 Observe the spark. This should be strong and highly visible. f not, remove and clean the spark plug as Section 8.2. Check that the spark plug gap is correctly set at 1.5 mm. 4 Check the pilot flame. f the pilot flame ignites and the unit goes to LOCKOUT, the scanning system is at fault. Remove and clean the detector as Section 8.2. Check the flame signal as in Section 4.3.1. 5 f the pilot does not light. the gas supply system is faulty. Check the pilot system for restriction, and the pilot valve operation. 6 f the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed, either the flow control valve is blocked, or one of the main gas block valves has failed. Fit a manometer on the pressure test point on the outlet flange of the multifunctional control and observe if the pressure rises when the main gas valves are addressed. No pressure rise will indicate failure of the main gas valves. JULY 1999 SAMPLE Page 32
7 FAULT FNDNG 3000R 7.5 AR FAN ON and DAMPER CRCUT PROVEN LGHTS LLUMNATED f the burner does not start, check: 1 SUMMEROFFWNTER switch is in WNTER position. 2 Overheat Limit Control These interlocks prevent the burner management system starting. JULY 1999 SAMPLE Page 33
8 SERVCNG 3000R MPORTANT Servicing and maintenance should be only carried out by a R.S. STOKVS Ltd. approved engineer. Only use replacement parts provided by the appliance manufacturer. Check that the air openings for combustion and for ventilation of any plant room or compartment are clear. 8.1 SOLATON 8.1.1 FUEL GAS SOLATON The fuel gas to the STOKVS ECONO AR 3000R Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line. Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed. 8.1.2 ELECTRCAL SOLATON All electric power to the air handler and the remote control station is switched through the local isolator. This isolator is fitted with a lock facility to permit it to be locked in the OFF position. Additionally isolate the power at the Wall solator. JULY 1999 SAMPLE Page 34
8 SERVCNG 3000R 8.2 ROUTNE MANTENANCE The air handler should be routinely serviced at the start of each heating season. solate the air handler as above before servicing. Details of access to individual components are given in Section 8.4 of this manual. 1 Remove and clean spark igniter. Check that the gap is correctly set at 2.5 mm. Replace every two years. 2 Clean the flame detector lens to ensure freedom from dirt and moisture. f the cell shows any sign of cracks it should be replaced. Routinely replace the cell every two years or after 10,000 hours of operation, which ever comes first. 3 nspect the entire air handler paint system for general damage. Repair as necessary. 4 Every two years brush the burner plates and clear the burner holes carefully with a Size 1.Bmm drill for NP and 2.0mm drill for NP. WARNNG: THE BURNER HOLES MUST NOT BE ENLARGED. 5 nspect and lubricate all damper linkages to ensure freedom of operation. Wipe off all excess lubricants to prevent dirt build up on linkage parts. 6 Check the fan belt for cracks and splits. Check tension. The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N. Adjust as necessary. 7 Grease both the fan shaft bearings with Mobi/ith AW2 grease, or similar. NEVER use high temperature grease. NEVER mix two different greases within the bearing, always flush existing grease out. Note: Removing the cover plate on the end of the air handler gains access to the outboard fan bearing. Clean Dry 120 1 t02 months Moderate to Light to Slow to 0 120 1 to 4 weeks Dry Dirty Medium Medium 120 200 1 to 7 days Light to Slow to Daily Flushing out Extreme Dirt Dry 0 200 Medium Medium Dirt 8.3 ANNUAL SERVCE CHECKS After Servicing, test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual, to ensure correct operation generally. Special attention must be paid to the damper system and related controls and interlocks. Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this, as necessary. JULY 1999 SAMPLE Page 35
8 SERVCNG 3000R 8.4 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS MPORTANT Turn off the gas at the appliance service valve and the electricity at the ma.in panel and wall isolator before proceeding. 8.4.1 BURNER The burner is located inside the air handler casing and is mounted on two brackets from the support straps. To remove the burner isolate the air handler as in 8.1 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail. Access to the rear of the burner assembly is made by removing the partition plate below the burner, separating the fresh air inlet to the burner from the return air inlet compartment. This is held in place by screws which engage in captive nuts on the top side of the partition. Remove the Flame Detector and pull off the ignition plug cap. Disconnect the burner support brackets and remove the burner. The burner will easily pass through the access hatch for 'further strip down. Replace in the reverse order, soundness test the gas pipework, check the burner operation and duty as described in the commissioning section of this manual. 8.4.2 FLAME DETECTOR This is a 240 Volt instrument. The flame detector is mounted on the end of the burner rail inside the air handler casing. To remove the detector, isolate the panel electric supply and lock off. Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount. Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections. Replace the flame detector in the reverse order ensuring correct polarity of connections. Ensure the access panel is securely closed and the retaining nuts are tightened down. Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 4.3.1). Operate the appliance over six starts for reliability of operation including turn off of start and main gas valves to check for lockout operation. 8.4.3 GNTER SPARK PLUG This is a high tension spark plug. The igniter spark plug is mounted on the end of the burner rail inside the air handler casing. To remove the spark plug, isolate the air handler as above. Enter the service access door. Access to the spark plug is made through the profile plate. To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner. When replacing the spark plug check the plug gap is set at 1.5mm. Check ignition reliability over six start ups. JULY 1999 SAMPLE Page 36
8 SERVCNG 3000R 8.4.4 GNTER SPARK TRANSFORMER This is a 240 Volt instrument. The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel. To remove the transformer, isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid. Disconnect the supply cable at the terminal strip and undo the transformer retaining screws. The transformer may then be 'unscrewed' from the High Tension cable leading to the spark plug. Replacement is a simple reversal of this procedure. Check ignition reliability over six start ups. 8.4.5 COMBUSTON AR PRESSURE SWTCH (DPS) Note: The switch is set and sealed and should be replaced if not operating correctly. This switch is a 240 Volt instrument. The air switch is mounted directly on the air handler casing and can be serviced in situ. However, if it is necessary to remove the switch, isolate the air handler as above. Disconnect the supply cable. Break the downstream pipe compression fitting and unscrew the switch housing 'from its locating fitting. Reverse the procedure to replace, after ensuring switch setting is as speci'fied in Section 1.3 of this manual. Operate the air handler to ensure reliability of operation over six start ups. 8.4.6 AR HANDLER OVERHEAT LMT CONTROL This is a 240 Volt instrument. The overheat limit control can be serviced in situ. However, if it is necessary to remove the control isolate the air handler as above and lock off. Remove the switch cover. Disconnect the supply cable and unscrew the control housing from its locating fitting. Reverse the procedure to replace, check the switch is set to 50 C. Test the switch operation as described in Section 4.3 over at least three operations. 8.4.7 RECRCULATON/FRESH AR DAMPERS and MOTOR The damper motor is a 24 Volt instrument. Access to the darrlpers and motor is from inside the air handler underneath the burner section. Normally these are maintenance free items. However, if it necessary to remove any of above, isolate as above and undo the motor linkage arm at the knuckle joint. To remove the motor, unbolt the motor from its mount. Disconnect the electric connection at the terminal strip under the motor lid. The dampers may be removed by unbolting them from their surrounding sleeves. Replacement is a simple reversal of the above procedure. Note that the damper to motor linkages are of fixed length and cannot be replaced incorrectly. JULY 1999 SAMPLE Page 37
8 SERVCNG 3000R 8.4.8 DAMPER MCROSWTCH This is a 240 volt instrument The damper microswitch is mounted on a bracket which forms part of the damper motor mounting. To remove the microswitch, unbolt the four retaining bolts and lift off. Disconnect the electric supply on the terminals below the access cover, after noting the wiring connections are as wiring diagram. Fit the replacement microswitch on the four mounting holes. To check the correct operation of the microswitch, disconnect the motor/damper linkage at the motor end joint. The fresh air and recirculation air dampers may now be operated by hand. Do not undo the linkages to either damper. Move the fresh air damper to the fully open position where it will engage on the microswitch striker arm. With a continuity meter, check that the microswitch is made, i.e. continuity across C and NO. Move the fresh air damper to the fully closed position and check that the microswitch is not made, i.e. continuity across C and NC. Now adjust the switching position, which is determined by monitoring the C and NO terminals, as above. Slowly move the fresh air damper towards the fully open position. Observe the switch change over point, which should be when the damper is within 100 of the fully open position. Adjustment is made on the striker arm to shaft fitting by slackening the locking Allen Key screw. The striker may then be moved on the shaft splines and re-ocked in place. Repeat the above checks until the switching point is correct. Reinstate the microswitch electrical connections and replace the casing cover. Refit the damper linkage to the damper motor and re-commission the air handler as described in Section 4 of this manual. 8.4.9 AR FAN AND MOTOR The air fan motor is a 415 Volt, 3 phase motor. The motor and slide rails are easily accessible inside the air handler casing. f it is necessary to remove the motor, isolate the air handler as above. Slacken the fan-belt tension and remove the drive belts. Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable. The motor may now be removed from the unit. Following replacement, the air handler must be fully recommissioned as in Section 4. t is unlikely that the air fan will need replacing or servicing. f required, a full procedure should be obtained from R.S. STOKVS Ltd. Replacement must be followed by full re-commissioning as in Section 4. JULY 1999 SAMPLE Page 38
8 SERVCNG 3000R 8.4.10 FUEL GAS MULT-FUNCTONAL CONTROL - SMALL UNTS This is a 240 Volt instrument. The fuel gas multi-functional control can be serviced in situ. However, if it is necessary to remove the unit, isolate the air handler as above. Disconnect the Hirschman electric termination. Unbolt the control from its 'Hanges and remove. When replacing, care must be taken to ensure the flange '0' rings are undamaged and in the correct location. Following replacement, the air handler must be fully recommissioned as in Section 4, including tests for soundness prior to start-up. 8.4.11 GOVERNOR AND BLOCK VALVES The block valves are 240 Volt instruments. All these items may be serviced in situ. However, if it is necessary to remove any item, isolate the air handler as above. Disconnect the electric termination to the two block valves, the pilot block valve and the 'How control block valve. Break the two pipe unions and remove the fuel gas line complete for further strip-down. 8.4.12 FUEL GAS FLOW CONTROL VALVE This is a 24 Volt instrument. The fuel gas flow control valve can be serviced in situ. However, if it is necessary to remove the valve, isolate the air handler as above. Disconnect the supply cables to the control valve. On small air handlers fitted with a multi-functional control, support the multi-functional control and unbolt its discharge 'Hange. Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down. On large air handlers fitted with separate block valves, it will be necessary to remove the fuel gas line complete, as Section 8.4.10 above. Following replacement, re-commission the air handler. Note: f the fresh air damper is not in the full open position, the heat input must not exceed the maximum heat input at recirculation condition speci'fled in the technical data section of this manual. JULY 1999 SAMPLE Page 39
8 SERVCNG 3000R 8.4.13 WORKSPACE PRESSURE CONTROLLER This is a 24 Volt instrument. The workspace pressure controller is mounted directly on the air handler casing and can be serviced in situ. However, if it is necessary to remove the switch, isolate the air handler as above. Disconnect the supply cable. Break the two compression fittings and unbolt the controller complete. Unless specified otherwise, R.S. STOKVS will supply a replacement pressure controller, pre-set and sealed with a set-point of 0.125 mbar (0.05 in w.g.). Replacing the controller is a straight forward reversal of the above procedure. After replacement, check the operation of the controller as Section 4.3.3. 8.4.14 PLOT GAS GOVERNOR AND BLOCK VALVE The block valve is a 240 Volt instrument. Both items may be serviced in situ. However, if it is necessary to remove either item, isolate the air handler as above. Disconnect the electric termination to the solenoid valve. Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3). Remove the pilot gas line complete for further strip down. Replace broken or distorted connections and retest for soundness. Ensure the pilot gas pressure is correct and the flame is sensing an output. Ensure reliability over six startups. JULY 1999 SAMPLE Page 40
8 SERVCNG 3000R 8.4.12 BELT TENSONNG PROCEDURE The setting tensions are designed to cover a wide range of drives. A precise setting force for individual applications can be calculated as detailed. SETTNG FORCES Belt Section SPZ SPA SPB SPC Small Pulley Diameter (mm) Setting Force To Deflect Belt 16mm per Metre Of Span. Basic Setting Forces Newtons (N) Kilograms (kgf) 1.25 x Setting Forces Newtons (N) Kilograms (kgf) 56 to 71 16 1.6 20 2.0 75 to 90 18 1.8 22 2.2 95 to 125 20.2.0 25 2.5 Over 125 22 2.2 28 2.8 80 to 100 22 2.2 28 2.8 106 to 140 30 3.0 38 3.8 150 to 200 36 3.7 45 4.6 Over 200 40 4.0 50 5.1 112 to 160 40 4.0 50 5.1 170 to 224 50 5.1 62 6.3 236 to 355 62 6.3 77 7.9 Over 355 65 6.6 81 8.3 224 to 250 70 7.1 87 8.9 265 to 355 92 9.4 115 12.0 Over 375 115 1~.0 144 15.0 JULY 1999 SAMPLE Page 41
8 SERVCNG 3000R BELT TENSONNG USNG FENNER BELT TENSON NDCATOR Calculate the deflection in mm on a basis of 16mm per metre of centre distance. Centre Distance (m) x 16 =Deflection (mm). Set lower marker ring at the deflection distance required in mm on the lower scale. Set upper ring against to bottom edge of the top tube. Place the belt tension indicator on top of the belt at the centre of span, and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt. Read off the force value indicated by the top edge of the upper marker ring. Compare this force to the kgf value shown in the table above. f a Fenner Belt Tension ndicator is not available, a spring balance and rule will be suffice. JULY 1999 SAMPLE Page 42
8 SERVCNG 3000R 8.5 MAN PANEL CONTROLS All panel controls are readily accessible and may be easily exchanged for replacement corrlponents in the event of failure. Ensure any replacement item is of the same make and type as the original. 8.5.1 LAN DS & GYR LFL 1.335 AUTOMATC SEQUENCE CONTROLLER The Landis & Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis. To remove the controller, undo the two retaining screws at the top left and lower right comers, and pull the module off the chassis. Replacement is a simple reversal of the above procedure. 8.5.2 CONTROLS CRCUT (24 VOLT) TRANSFORMER The Controls Circuit Transformer is fixed to the panel back plate by tapped screws. To remove the transformer, undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel. Undo the two retaining screws and remove the unit complete. Replacement is a simple reversal of the above procedure. 8.5.3 CONTROL RELAYS, R1, R2 & R3 The Control Relays are DN Rail mounted. To remove a relay, undo the wiring connections after first noting that the connections are correct to the wiring diagram, attached to the panel. Release the DN rail retaining clip under the relay with a screwdriver and remove the relay. Replacement is a simple reversal of the above procedure. 8.5.4 6A MCB The 6A MCB is DN Rail mounted. To remove the MCB, undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel. Release the DN rail retaining clip under the MCB with a screwdriver and remove the MCB. Replacement is a simple reversal of the above procedure. 8.5.5 THERMAL OVERLOAD The thermal overload is attached to the underside of the main contactor. To remove the overload, undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel, and that the overload setting is as speci'fied in Section 1.3 of this manual. Unscrew the three connections to the contactor and remove the overload. Replacement is a simple reversal of the above procedure. JULY 1999 SAMPLE Page 43
8 SERVCNG 3000R 8.5.6 MAN CONTACTOR The Main Contactor is DN Rail mounted. To remove the co ntactor, remove the thermal overload, as 8.5.5 above, and then undo the wiring connections, after first noting that the connections are correct to the wiring diagram attached to the panel. Release the D N rail retaining clip under the contactor with a screwdriver and remove the contactor. Replacement is a simple reversal of the above procedure. 8.5.7 MOTOR FUSE To replace a motor fuse pull the fuse carrier off the fuse holder base. The fuse is attached to the fuse carrier by two screws. Unscrew, remove and replace. 8.6 REMOTE CONTROL STATON The remote control station contains some serviceable parts, although these items should only be fitted by an approved R.S. STOKVS Ltd. Engineer. JULY 1999 SAMPLE Page 44
9 RECOMMENDED SPARES 3000R For two years operation, it is recommended that the following items should be held in stock: TEM DESCRPTON PART NO. QUANTTY 1 NDCATOR BULBS W1121 1 PACK 2 SPARK PLUG 023739 1 3 UVDETECTOR QRA10 1 4 ROOM SENSOR DRT.2453 1 5 DUCT SENSOR DDT.1701 1 All replacement parts can be obtained from R.S. STOKVS Ltd. by quoting the air handler serial number, the part number and description. JULY 1999 SAMPLE Page 45
APPENDX 1 3000R SOUNDNESS TESTNG THE FUEL GAS PPEWORK This procedure should only be carried out by personnel familiar with the STOKVS ECONO AR 3000R Series Air handler. The pressure test points and all valves are identified on the Process and nstrumentation Diagram for the air handler included in Section 1 of this manual. solate the air handler electric supply at the main control panel and lock off. Close the manual isolation valves MV1, MV6 and PV3. Ensure the supply pressure is available on the upstream side of MV1. A1.1 TESTNG THE UPSTREAM PPEWORK AND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A. Monitor the pressure for two minutes. Any rise in pressure indicates that valve MV1 is leaking and must be replaced. Remove pressure test points Band F. 2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve. 3 Close MV1. Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure. f the pressure falls, open valve MV1 and test the pipework connections and valves from MV1 to MV3, and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray. Turn off MV1, seal any leaks and re-test. 4 f no extemalleaks are found either the pilot block valve, PV1, or either the first main gas block valve, MV3, is letting by. 5 To test this, seal pressure test point A and fit a manometer to pressure test point B. Leave for two minutes with MV1 open. A rise in pressure on the manometer confirms a leak on the block valve, MV3. Turn off MV1, exchange the valve and re-test from point 2 above. 6 Repeat this procedure for the pilot block valve: Seal test point B and fit a manometer to pressure test point F. Leave for two minutes with MV1 open. A rise in pressure on the manometer confirms a leak on the pilot block valve, PV2. Turn off MV1, exchange the valve and re-test from point 1 above. Seal test point F. JULY 1999 SAMPLE Page 46
APPENDX 1 3000R A1.2 TESTNG THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and B with flexible 6 mm bore tubing teed into the manometer. Remove pressure test point C. Open MV1 to pressurise the downstream block valve, MV4. 2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor the pressure for 2 minutes. f the pressure falls, open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector. Turn off MV1, seal any leaks and re-test. Note: Smaller air handlers in the 3000 Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component. The above procedure still applies, but if a leak is found on either block valve, the whole control should be replaced. f no external leaks are found, the downstream block valve is letting by_ 3 To confirm this, close MV1, remove the manometer and refit to pressure test point C. Connect pressure test points A and B with flexible 6mm bore tubing. Open MV1 and allow one minute for the temperature to stabilise. Monitor the pressure for a further 2 minutes with MV1 still open. A rise in pressure confirms that the second block valve MV4 is letting by. Turn off MV1. Replace the valve and re-test from 2 above. A1.3 TESTNG THE DOWNSTREAM BURNER PPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore tubing teed into the manometer. Open MV1 to pressurise the downstream pilot pipework. 2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor the pressure for 2 minutes. f the pressure falls, open valve MV1 and leak test the line between the downstream block valve, MV4 and the manual block, MV6 with a proprietary leak detector fluid or spray. f no external leaks are found the manual block valve, MV6, is letting by_ Turn off MV1, seal any leakages and retest from 2 above. A1.4 TESTNG THE DOWNSTREAM PLOT PPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore tubing teed into the manometer. Open MV1 to pressurise the downstream pilot pipework. 2 Close MV1 and leave for one minute for the temperature to stabilise. Monitor the pressure for 2 minutes. f the pressure falls, open valve MV1 and leak test the line between the downstream block valve, PV2 and the manual block, PV3 with a proprietary leak detector fluid or spray. f no external leaks are found, the manual block valve, PV3 is letting by_ Turn off MV1, seal any leakages and retest from 2 above. JULY 1999 SAMPLE Page 47