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INSTRUCTION MANUAL
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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS FOR
PAKAWAY GAS FIRED AIR HEATERS
THESE AIR HEATERS ARE FOR USE WITH NATURAL GAS ONLY
,; Pakaway, whose policy is one of continuous development and improvement, reserves the right to alter any
-~ specification appearing in this manual without notification.
If in any doubt on the interpretation of any instructions in this manual, please contact the Pakaway Sales
Office, address and telephone number as on back cover.
Appliances asterisked have been approved by British Gas for use on natural gas.
G.C. numbers:
300 VNG3 42 534 01
, . ..'. 600
~ .'
VNG3 42 534 04
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CONTENTS
1B General requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1F Boosted supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1J Electrical supply . . . .. .... . .. . . . .. . .. .. ...... ... ... . . .. ... . .. . . . ... .. .... . .. . .. . ........ 7
3B Control chassis check . .. ... . ......... . ......... . .. . .... . ........ . . .. . ... .............. . 11
3C Time switch chec.k .. ... .... . ............... . .... . . . . . ... . ........ ... . .. . .. .... . ... . ... . 11
3K Gas supply check . . . ... . .................. .... . . ................. . ..... . ........ . ..... . 12
3M Gas soundness testing of the gas line - Heater models 100 & 150 . . . ... .. ........ .. . . . 13
3N Gas soundness testing of the gas line - Heater models 200 & 300 VNG ... ..... . .... . . 14
30 Gas soundness testing of the gas line - Heater models 400 & 500 VNG3 ... . ......... . 15
3P Gas soundness testing of the gas line - Heater models 600, 800 & 1000 VNG3 ....... . 16
3X Users instructlions - Advice to user . .. . .. . . ... ........... . .... .. .... .. .... . ........ .. .. . 19
7E Combustion head adjustment - Gas 2 burner . . .. ... . . . ... . .... .. .. . ........... . . ... .. . 27
7F Air pressure switch adjustment ........ . ... ... ... . ........... . ...... .. ............ . ... . . 27
1B GENERAL REQUIREMENTS
The installation of the air heater(s) must be in accordance with the relevant requirements of the Gas
It should be in accordance also with any relevant requirements of the L.ocal Gas Region, Local Authority
and Fire Authority and t'he relevant recommendations of the British Standards Codes of Practice.
CP.331 Part 3:- Installation of pipes and Meters for Natulr al Gas.
British Gas Publication No. IM/11:- Flues for Commerciall and Industrial Gas Fired Boilers and Air Heaters.
1WAH MA Publication No. 2:- Standards of Installation for Gas Fired Industrial Warm Air Heaters.
The above related documents are, from time to time, revised and additional documents published. Whilst
every effort is made to keep literature current, Pakaway cannot be responsible for this listing being correct
1C WARRANTY
Please refer to the 'Conditions of Sale' printed on the reverse side of the Sales Acknowledgement, copies
of which can be supplied separately if requested from the Pakaway Sales Office.
Pakaway cabinet heaters are supplied backed by an extensive guarantee. The heater unit carries a
twenty-four month guarantee on all parts commencing from the wor'ks despatch date. In addition, the
I Note: Notification is required immediately a fault is suspected, otherwise no responsibility can be taken
for further damage, or expense incurred if other means are used to carry out rectification works.
5
10 LOCATION
The location chosen for the air heaters must permit the provision of a satisfactory flue system and an
adequate air supply. The location must also provide adequate space for servicing and air circulation
around the air heater.
The air heaters must be installed str~ctly in accordance with any fire regulations or insurance company's
requirements appertaining to the area in which the heater is located, particularly where special fire risks
are involved such as areas where petrol vehicles are housed, where cel'lulose spraying is carried out, in
woodworking departments, etc.
The air heaters must be installed on a level non-combustible surface which is capable of adequately
supporting the weight of the air heaters and any ancillary equipment. The heaters must be stable or rigidly
fixed in order to prevent hazard to personnel.
The air heaters must not be installed in conditions for which it is not specifically designed, e.g. where the
atmosphere is highly corrosive or salty and where high wind speeds may affect burner operation.
If the location of the air heater is such that it might suffer external mechanical damage, e.g. from overhead
cranes, fork lift trucks, it should be suitably protected.
Any combustible material adjacent to the air heater and the flue system must be so placed or shielded as
to ensure that its temperature does not exceed 65°C (150°F).
1E GAS SUPPLY
Service pipes
The local gas region should be consulted at the installation planning stage in order to establish the
availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the local gas region.
Meters
A gas meter is connected to the service pipe by the local gas region or a local gas region contractor.
An existing meter should be checked, preferably by the gas region, to ensure that the meter is adequate
to deal with the rate of gas supply required.
Installation pipes
Installation pipes should be fitted in accordance with British Standards Code of Practice No. CP331:3.
Pipework from the meter to the air heater must be of adequate size. Do not use pipes of smaller size than
the air heater gas connection.
The complete installation must be tested as described in the above code.
1F BOOSTED SUPPLIES
Where it is necessary to employ a gas pressure booster the controls must include a jow pressure cut-off
switch at the booster inlet.
The Ilocal gas region must be consulted before a gas pressure booster is fitted.
1G FLUE SYSTEM
Refer to British Gas Publication No.1 M/11 - Flues for Commercial and Industrial Gas Fired Boilers and
Air Heaters.
The Pakaway heaters do not require a draught diverter, they are supplied with an integral flue-box all owing
for the direct connection to an individual open-flue system.
Materials used for the flue system should be mechanically robust, resistant to internall and external
corrosion, non-combustible and durable under t he conditions to which they are likely to be subjected.
Prevention of condensation within the flue shou lld be an important factor in the design o~ the flue system.
In order to minimise condensation the use of double walled flue pipe or insulation is recommended. If
double walled flue pipe is used it shou ld be of a type acceptable to BriHsh Gas.
Where condensation in the flue is unavoidable provision should be made for the condensate to flow freely
to a point at which it can be released, preferably into a gully. The condensate pipe from the flue to the
disposal point should be of non-corrodible material of not I'ess than 22mm (%in) size.
Facilities should be made for disconnecting the flue pipe from the air heater for inspection and servicing
purposes. Bends with removable covers should be fitted for inspection and cleaning purposes where
considered appropriate.
The flue system should ensure safe and efficient operation of the air heater to which it is attached, protect
the combustion process from wind effects, and disperse the products of combustion to the external air.
The flue should terminate in a freely exposed position and must be situated so as to prevent the products
of combustion entering an opening in a building in such concentration as to be prejudicial to health or a
nuisance.
It i's recommended that a terminal be fitted at the flue outl'et.
6
1H AIR SUPPLY
The basic minimum effective area requirement of the air vent is as follows:
Gas
heater model Air vent area per heater
I 100
150
180cm~
270cm~
(28in~)
(42in~)
200 360cm~ (57 in A)
A
300 523cm (80inA)
A
400 707cm (107inA)
A
500 883cm (134in~)
A
600 1060cm (160inA)
A A
1850cm (280in~)
A
1000
1J ELECTRICAL SUPPLY
Wiring external to the air heater must be installed in accordance witlh I.E.E. Wiring Regulations and any
local regulations which apply.
Models 100 to 300 are normally supplied for 240 volts, 50Hz, single phase, neutral and earth.
Models 400 to 1000 are normalily supplied for 415 volts, 50Hz, 3 phase, neutral and earth.
The method of connection to the mains electricity supply must facilitate complete electrical isolation of
the air heater by an isolator having a contact separation of at least 3mm in all poles for three phase and
1.5m separation on single phase and the supply must serve only the air heater. The method of connection
should be provided adjacent to the air heater in a readily accessible position.
For wiring instructions see page 31 .
7
GENERAL ARRANGEMENT OF CABINET & ACCESSORIES
Flue Pipe
Burner
~=-=:.-..-::-,++----- Ti me Clock
Control Chassis
Thermal
Insulation
Mark II
Air Inlet Panel
Ventilated
Heat Shield Main Fan Drive Motor (Indirect Drive)
on Mark II I
Direct Drive Fans fitted on mode ls 100 to 300
8
Section Two - Installation of A,i r Heater
2A HEATER UNPACKING
The air heaters are despatched as follows:
1) Air heater complete with burner and flue box, all protected by plastic sheeting.
Note: Gas train may be disconnected from the burner and stowed in the heater fan compartment.
2) Air heater to~ plate dispatched separately. } N t I' ble t d ct head models.
3) Air nozzles dispatched separately. 0 app Ica 0 u
After heater is correctly positioned, locate heater top plate over spigot provided and then place air nozzles
over outlets in top plate.
The air heater is to be floor-mounted on a level non-combustible surface which is capable of carrying the
weight of the air heater and any ancillary equipment. See data sheet on page 25.
28 INSTALLATION CLEARANCES
The space in which the heater is to be fitted must have the following minimum dimensions:
Heater model Width Depth Height
100 & 150 1000mm (40in) 1525mm (60in) 2800mm (110in)
200 & 300 1000mm (40in) 2000mm (80in) 3000mm (120in)
400 & 500 1400mm (55in) 2200mm (87in) 3500mm (138in)
600 1400mm (55in) 2600mm (104in) 3650mm (144in)
800 1650mm (65in) 2450mm (98in) 3950mm (155in)
1000 1650mm (65in) 2550mm (102in) 3950mm (155in)
In addition to the dimensions mentioned above the following minimum clearances must be available at the
front of the heater on heater models 800 and 1000, at the back of the heater also on heater models 100
to 600 to enable heater to be serviced.
Heater model Clearance
100 & 150 760mm (30in)
200 & 300 1000mm (40in)
400 & 500 1000mm (40in)
600 1000mm (40in)
800 1270mm (50in)
1000 1270mm (50i n)
material. If a draught stabiliser is fitted, check that it is in the closed pOSition. Check that it is free to move
and not prevented from swinging by foreign objects or damaged in any way.
It Is imperative that where a flue passes through roof, this opening is properly sealed by roof plate
and cravat to ensure no water e nters.
NO CLAIMS FOR ANY DAMAGE RESULTING FROM INGRESS OF WATER WILL BE CONSIDERED.
Flue pipes must not have sharp bends. Easy obtuse bends are necessary to assist the flow of gases. Flue
terminal cowls as demanded by site conditions are necessary.
Care must be taken that the flue height and materials used, meet all the necessary requirements and
codes. (Refer to General Requirements on page 5 of these instructions.)
20 GAS CONNECTION
Heater models 100, 150, 200, 300, 400 & 500
Fit burner gas train to burner at union connection on the underside of blast-tube, the gas train can be
positioned for either left or right hand gas supply pipe connection.
Fit the two electric plugs on the flying leads from the gas train into the sockets located on the back face of
the burner, these plugs are not interchangeable.
Heater model 600, 800, 1000
Fit burner gas train to burner at flange connection on the underside of blast-tube using gasket and fixings
·supplied. The gas train can be positioned for either left or right hand gas supply pipe connection.
Fit the three electric plugs on the flying leads from the gas train into the sockets located on the underside
of the burner housing. (Note: The 3 pin plugs on the pilot gas valves can be safely interchanged.)
The gas pipework should be sized to produce the required gas volume so that at least the minimum inlet
pressure (see page 25) is obtained to the burner manifold, to give the required head pressure.
9
The local gas region prefer to be consulted regarding each installation and they will advise as to the
pressure of gas supply and the recommended pipe sizes for single or multi-heater installations.
Note: Each heater must be fitted with a gas supply isolating cock and a suitable union. (The cock to be
upstream and adjacent to the union which in turn must be upstream of the burner outlet.)
These items can be supplied as an optional.
Under no circumstances must the gas pipework be used as an electrical earth.
2E ELECTRICAL CONNECTIONS
Note: All electrica'i wiring and connections must be made in accordance with the I.E.E. regulations. Check
any local regulations that apply, Le. garage installations or hazardous environments.
Check rating plate on heater for supply voltage requirements. Connect supply from a suitably fused
isolator or a local isolator on a suitably fused supply to the mains terminal strip in the wiring chassis of the
air heater (see wiring diagram on page 31).
Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.
All external wiring must be enclosed within approved conduit. Conduit from isolator switch must run so as
not to interfere with service panels of the air heater.
Whether a single heater or a number are to be wired as part of a single installation, an isolator must be
provided, so that each heater can be separately d,i sconnected. The isolator switch shouId be located in a
readHy accessible position. Each heater should be independently fused.
Controls from one heater to another heater must not be interwired.
I~
r,
I
IiIi
Section Three - Commissioning and Testing
3A PRELIMINARY PRECAUTIONS
All heaters must be commissioned. test fired and serviced by a competent gas engineer.
a) Before attempting any check; switch off electrical supply to heater at main isolating switch
and remove fuses.
b) Shut off main gas isolating cock to unit.
Note: The unit is·not isolated electrically until the main isolator is switched off and the fuses are removed.
Switchi,ng off at the summer/winter switch ils not sufficient when work is being carried out on the unit.
Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.
Check that all wires on control chassis are secure, and tHat no strands of multi-strand cables are near, or
3E FROST THERMOSTAT
This is wired across switched circuit by-passing the time switch control and wil l not effect commissioning
and testing whilst time switch is on ON cycle.
Check and ensure that the combination fan I'imit thermostat settings are as specified below:
Check that the door is free to open and that it is not obstructed in any way by piping etc.
3H FAN CHECK
Remove screws retaining air inlet panel and remove panel for access to fan.
Rotate fan by hand to check that it is running freely, and that it is free from foreign bodies in the fan
blades.
Check fan belt tension which should give approximately 6mm (1/4in) belt movement up and down at mid
001 t. Adjust by moving motor on slide rails.
Jc k tightness of fan shaft bearing locking coHars.
,,
Move summer/winter switch to 'Summer' to run fan only. Fan should run in direction giving the most air
volume from the unit. If it runs in the reverse direction, return switch to OFF, turn off electrical supply at
. main isolating switch and remove fuses. Then reverse any two of the incoming phases at the heater
terminal block. Replace fuses. Turn on isolator. Check again for correct rotation. Return switch to OFF
position.
Models 100/300 have single phase direct drive fan units. Check details as applicable.
Check main burner isolating gas tap operates freely. Open and close by hand.
Check supporting arrangements of the pipeline to ensure that lines are correctly supported and that
The whole of the gas installation incl uding the meter, should be inspected and tested for soundness and
purged in accordance with the recommendations of British Standard Code of Practice 331 :3.
3L BURNER CHECK UP
Turn OFF gas at main isolating tap and electrical supply at main isolating switch.
Reillo gas burner on heater models 100, 150, 200, 300, 400 & 500
Remove the burner cover by loosening the three retaining screws and then pull cover away from burner.
Remove the two electrical plugs (one plug on models 100/150) on the flying leads from the gas train from
Remove top of burner fan housing by undoing securing screw, this gives access to the leads to the
Remove leads from the electrode and flame probe, tlh e burner can now be separated from the blast tube
and firing head by loosening the nut and turning the latch at the top front of the blast tube.
Remove the socket head screw (1) on page 27 and remove firing head (2) from blast tube (Section 7E).
Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked
in the factory and should not require re-setting. Replace firing head (Section 7C).
Firing head setting
Two separate adjustment settings have to be made; one for the air and one for the gas. Refer to table on
page 25 for setting numbers.
Method for air-setting (Refer page 25, Section 7 E)
Loosen the screw (1), move the firing head (2) so that its rear edge (3) is level with the desired setting
Loosen the screw (5), move the ring (6), so that the pointer (7) is level with the desired setting number (8).
Replace the burner to the blast tube and replace latch and tighten nut.
· Replace Il eads to electrode and flame probe and replace fan housing cover.
Replace the electric plugs on the flying leads from the gas train into the sockets located on the back face
, ?
Reillo gas 3 burner on heater model 600, 800 & 1000
Remove the three electric plugs on the flying leads from the gas train from the sockets on the underside
Separate the firing head from the rest of the burner by removing the two screws (1) on page 27 and
The action of puHing the burner-body from the firing head will release the leads from the electrode and
flame probe.
Remove the two socket head screws (1) on page 28 and remove firing head (2) from blast tube
(Section 7H).
Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked
Two separate adjustments have to be made; one for the air and one for the gas. Refer to table on page 25
Loosen the two screws (1) and move the firing head (2) so that it's rear edge (3) is level with the desired
Loosen the screws (5), move the ring (6) so that the pointer (7) is Ilevel with the desired setting number (8).
Replace the burner-body to the blast tube making sure the leads to the electrode and flame probe are re
connected, the use of pliers will help in connecting the two leads. Replace the two securing screws.
Replace the electric plugs on the flying leads from the gas train into the sockets located on the underside
of the burner housing. (Note: the 3 pin plugs on the pilot gas valves can be safely interchanged.)
EstabHsh type of gas train fitted, that is conventional or CG Monobloc. Use appropriate testing scheme.
3M GAS SOUNDNESS TESTING OF THE GAS TRAIN - HEATER MODELS 100 & 150
T cr::::::>>+-I--~c:>tJ· :f c:G1------~f-------.-
A, B Manual shut off valves
1 Main governor
3 Operating valve
1. Switch off the heater. Isolate the electrical supply and close manual gas valves A & B.
Testing the pipework up to the upstream safety shut off valve
2. Connect a water column pressure gauge to pressure test point P1.
3. Open valve A to pressure the assembly up to the seat of the safety shut off valve.
4. Close valve A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If pressure
falls, open valve A and test for leaks with soap solution. Make good as necessary and recheck. Note:
Two minutes should be allowed for all soap solution tests.
Testing upstream safety shut off valve
5. Close valve B and open valve A Connect the pressure gauge to test point P2. If a rise in pressure is
observed then the safety shut off valve seat is paSSing. Make good and recheck.
and retest.
8. If the pipework is not leaking then the operating valve seat is paSSing. Make good and retest.
13
3N GAS SOUNDNESS TESTING OF THE GAS TRAIN - H'EATER MODELS 200 & 300
Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off valve
2. Connect a water column pressure gauge to pressure point P1.
3. Open valve A to pressurise the governor assembly.
4. Close A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls. open A and test for leaks with soap solution. Make good as necessary and recheck.
Note: Two minutes should be allowed for all soap solution tests.
5. If no external leaks are observed, the upstream safety shut off valve is passing.
To check this remove the screw from pressure test point P3 and depressurise the space between the
safety shut off valves.
Connect the water column pressure gauge and leave for 2 minutes with A still open. A rise in
pressure confirms the first valve is passing. Make good and recheck for soundness.
Testing the downstream safety shut off valve & pilot safety shut off valve
6. Close valve A and connect pressure test points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the assembly up to the seats of the downstream safety shut off valve and
pilot safety shut off valve.
8. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
faUs, open A and test the pipework connecting the safety shut off valve for leaks with soap solution.
Make good as necessary and recheck.
9. If no external leaks are observed either the downstream safety shut off valve or the pilot safety shut
off valve is passing. To check this remove the screw from pressure test point P4 and depressurise the
downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P4
and leave for 2 minutes with A still open. A rise in pressure confirms the downstream safety shut off
valve is passing. Make good and recheck for soundness. Then remove the pressure gauge from test
point P4 and connect to test point P6 and leave for 2 minutes with A still open. A rise in pressure
confirms the pilot safety shut off valve is passing. Make good an d recheck for soundness.
Testing the downstream pipework
10. Close valve A and connect pressure test points P2 and P4 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open A and test for leaks in the pipework downstream of the safety shut off valves with soap
A
P5
A B
P1
P5
3 4
A P1 P2 P3 B
--,.~.--~~---~~===c:I==r1~__~~-r=~~~.~_
A, B Manual shut off valves
P1, P2, P3 - Pressure test pOints
C Main block
Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A & B.
Testing the upstream pipework to the block
2. Connect a water column pressure gauge to P1.
3. Open A to pressurize to block.
4. Close A. Leave for 2 minutes. If pressure falls test for leaks with soap solution between A and block.
Make good as necessary and recheck.
Note: Two minutes should be aillowed for all soap solution tests.
Testing the first stage valve
5. Connect water column pressure gauge to P2 and open A If a pressure rise is observed the first stage
valve seat is passing. Rectify or replace and recheck.
Testing the downstream pipework for the block
6. Close A. link P1 and P3 with rubber tube and via a T piece connect a water column pressure gauge.
Open A to pressurize the system. Close A and leave for two mi,nutes. If a fall in pressure is observed,
test for leaks between the block and B. Make good as necessary and recheck.
Testing the second stage valve
7. Link P1 and P2 with rubber tube. Connect water column pressure gauge to P3. Open A If a pressure
rise is observed then the second stage is passing. Rectify or replace and recheck.
~I
I
ST HOLD SCREW
•
PS PG
17
Use 2.5mm Allen Key to adjust - DO NOT FORCE.
PS - Adjust the start gas pressure
PG - Adjust the main gas pressure
ST - When released 1-2 turns holds the control on start gas rate
Initial start of burner and adjustment
1. Release screw ST 1-2 turns.
2. Set control PS to a low value on scale and ensure control PG is set to a low value but slightly greater
value than that of control PS.
3. Start burner and set control PS to give an increase in pressure of 0.5" wg. (1.25 mbar) at the burner
head over the proving air value.
4. Close screw ST.
5. Set control PG to give specified burner head pressure.
The transfer from start to main gas is automatic and occurs 5-7 seconds after PS is energised or 5-7
seconds after screw ST is closed.
v) Switch on the mains electricity supply to heater. The heater should now start.
Motor
Ignition transformer
Main flame
listed -in data sheet on page 25. Adjust the pressure if necessary at the gas governor in the gas train line
The main burner pressure test point is located at the side of gas inlet to the burner head.
3T COMBUSTION CHECK
When the correct gas pressure has been established, adjust the combustion air shutter at the burner to
give carbon dioxide (C02) reading at the flue outlet of 8.5 to 9.0%.
Secure the air shutter.
The flame can be viewed from the viewing port on the burner or from the explosion relief door on the back
face of the heater on models 100 to 600 and on front face of heater on 800 and 1000 models. Care
should be taken when doing this as it is a pressurized combustion chamber.
IdeaUy the burner flame should be close to the burner head, pale blue in colour and have sl'ightly whitish
yellow tips to the flame end. The flame must not impinge on the end or side of the combustion chamber.
valve closes.
Then turn the knob back by two turns and restart the burner, thereby checking that it functli ons correctly,
should the burner again go to lockout, turn the knob back by one more full turn.
3W GENERAL
When all checks are complete replace the burner cover and tighten the three retaining screws. Finally
recheck the combustion to make sure that the fitting of the burner cover has not altered any conditions.
Re-adjust all controls to suit customers requirements.
Note: During all tests when the burner is firing the main heater fan operates independently under control
of the fan thermostat.
When servicing is completed, replace the fuses and switch on main electric supply.
Light the heater and carry out all the tests as described in the Commissioning and Testing Instructions.
Quote heater model, serial number and code number when ordering spare parts.
Remove the access covers on the flue box and brush the flue ways, flue box and flue system.
Remove all loose carbon material before replacing the access covers.
2. Clean main fan and housing and check fan belt tensions
Remove front and back air inlet pane,ls for access to fan housing.
Clean main fan of dust, paper etc. and check bearings for wear.
Check tightness of belts, pulleys on fan and motor shafts, tighten set screws if necessary.
Check fan belt tension which should give approximately 6mm (1f4in) belt movement up and down at mid
Note: Some units are fitted with direct drive main fans - if so, omit only the above references to belts and
pulleys.
Before replacing front air inlet panel examine the electrics for loose connections and check reset button(s)
operate freely.
Replace front air inlet panel.
3. Burner servicing
Riello Gas burner on heater modells 100, 150, 200, 300, 400 & 500
Remove the electric plugs on the Hying leads from the gas train, from the sockets on the back face of the
burner.
After removing the burner cover, remove top of burner fan housing by undoing securing screw. This gives
Remove these leads and the burner can now be separated from the blast tube by loosening the nut and
Remove the socket head screw and remove firing head from the blast tube. Brush clean if necessary.
Check that the ignition electrode and flame probe are pOSitioned as shown on page 26, also clean
electrodes and check porcelains for hairlline cracks, dust and carbon.
Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the Commissioning
Replace the burner to the blast tube and replace latch and tighten nut.
Before replacing leads to electrode and flame probe make sure the burner fan ,housing and all burner
Re-connect the plugs on the flying leads from the gas train into the sockets on the burner.
Remove the three electric plugs on the flying leads from the gas train, from the sockets on the underside
Separate the firing ,h ead from the rest of the burner by removing the securing screws and withdrawing the
The action of pulling the burner-body from the firing head will release the leads from the electrode and
flame probe.
Remove the two socket-~ead screws and remove firing head from the blast tube.
Check that the ignition electrode and flame probe are positioned as shown in page 26. Also clean
electrode and check porcelains for hairline cracks, dust and carbon.
Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the CommisSioning
21
Section Five - Fault Finding
FAULTS AND REMEDIES
Before making any adjustments ensure that the burner is electrically isolated.
Burner fails to start
1. One of the controls in the circuit not making contact such as the time switch, room thermostat, limit
thermostat or the air pressure switch.
2. Burner control box locked-out.
3. Check electrical supply.
Burner starts, fails to light and locks-out
1. Check gas supply, gas va lves and pressure settings. Re-purge if necessary.
2. No spark at electrode. Check electrode setting.
3. Spark does not ignite gas. Check electrode setting.
4. Check for flue blockage.
Burner motor starts, but not the control box sequence
11. The air pressure switch does not close its contacts. Check setting of air pressure switch. Replace if
defective.
Burner ignites and then locks-out
1. Flame probe incorrectly set. Check setting.
2. Excessive combustion air causing flame to lift off burner head.
3. Insufficient gas. Check gas supply.
4. Gas pressure too high. Check gas rate and pressure.
5. Check air pressure switch.
6. Check earth connections are secure and wired correctly to a good earthing source.
Burner locks-out during pre-purge or after shutdown
1. Flame sensed, ch eck gas valves.
2. Check control b ox, replace if defective.
Burner pu ,l sates when running
1'. Overiiring. Check gas rate.
2. Incorrect mixture. Adjust burner.
Insufficient air supply from main fan
1. Loose or worn fan belt(s), pulleys insecure.
2. Incorrect fan rotation (three phase). See page 11, Section 3H - Fan Check.
3. Air inlets obstructed.
4. Fan blades choked.
5. Excessive external air resistance.
Noisy main fan
1. Loose or worn fan belt(s).
2. Loose or worn bearing locking caps.
3. Worn bearings.
4. Pulleys insecure.
5. Paper etc. in fan causing imbalance.
6. Worn or dry motor bearings.
7. Loose fan support.
Fan starts when isolating switch is turned on but summer/winter is in OFF position
1. Make sure the fan limit combination is set to auto, i.e. white button pulled outwards.
22
Section Seven - Technical Data
7A DATA SHEET MK II Sept. 1987
HEATER MODEL 100 150 200 300 400 500 600 800 1000
I RIELLO GAS 3
GAS H GAS I GAS I GAS 2 GAS 2 GAS 2 GAS 3 GAS 3
BURNER TYPE
BURNER mbar 3.68 4.9 6.1 4.9 6.1 7.2 6.8 6.86 8.09
GAS SETTING
PRESSURE ins.wg. 1. 5 I 2.0 2.5 2.0 2.45 2.9 2.73 2.8 3.3
BURNER AIR
N/A 2 2.75 1 3 5 1 3 3
SETTING
1
BURNER GAS
2 2 2.75 0 3 4 0 7 7
SETTING
BURNER GAS 34" BSP 1" BSP 1" BSP 1V2" BSP
'12 " '12 " '12" 1" BSP 1" BSP
INLET EXT INT INT INT
EXT EXT EXT EXT EXT
CONNECTION
MIN INLET mbar 12.5 10.29 13.48 14.0 113.0 14.2 13.5 14.0 14.46
PRESSURE
TO OBTAIN ins.wg. 5.1 , 4.2 5.5 5.8 52 5.7 5.42 5.8 5.9
HEAT INPUT 1 .
MAX INLET
mbar 20 20 20 20 I 20 20 20 20 20 .
PRESSURE ins.wg. 8 8 8 8 8 8 8 8 8
HEATER MODEL 100 150 200 300 400 500 600 800 1000
BURNER GH G 1 G 1 G2 G2 G2 G3 G3 G3
mbar 3.7 4.9 6.1 4.9 6.1 7.2 6.8 6.9 ! 8.0
HEAD
PRESSURE ins.wg. 1.5 3.3
2.0 2.5 2.0 2.5 2.9 2.7 2.8
BURNER AIR SHUTTER N/A 2.0 2.8 1.0 3.0 5.0 1.0 3.0 3.0
20 20
MAX. GAS I mbar 20 20 20 20 20 ' 20 20
INLET PRESS. 8 8
ins.wg. 8 8 8 8 8 8 8
I HEATER MODEL 100 150 200 300 400 500 600 800 1000
I
BURNER GS 5 1 GS 5 GS10 GS10 GS 20 GS 20 GS 20 G3 G3
BURNER AIR SHUTTER 2.0 3.6 2.5 4.0 3.6 4.5 5.5 7.0* 7.0*
I
BURNER GAS HEAD 1.8 3.0 3.0 4.0 2.5 3.5 3.9 3.0 3.0
mbar < 12.0 < 12.0 < 12.0 13.5 < 12.0 12.0 14.5 14.0 14.5
MIN. GAS
INLET PRESS. ins.wg. 5.9
i < 5.0 5.0 < 5.0 5.5 < 5.0 5.0 6.0 5.8
*Internal setting. NOT shutter. t With CG Monobloc gas trains only. Standard gas train value 20mm (8").
7C ELECTRODE SETTINGS
-+-+---'"-li- E
E
v
+
cry
IMPORTANT
Don't turn the ionisation probe, but leave it in the position as shown on the figure above; if moved towards
the ignition electrode the amplifier of the control-box could get damaged.
70 IONISATION CURREN.T
The minimum safe level of ionisation current to enable the control-box to operate correctly and detect a
gas-flame is 2 uA (two micro amps).
The control box will of course, under normal circumstances, never be required to operate under such a
small signal condition, by correctly positioning the flame electrode.
To test the ionisation current (and hence the flame signal strength) a direct current micro-ammeter should
be inserted in series with the flame electrode. as per diagram.
Ammeter
--------4c:
Cable
----+~BI-----4c: :3
Flame probe
7E COMBUSTION HEAD ADJUSTMENT - GAS 2 BURNER
Two separate adjustments have to be made. one for the air and one for the gas settings; these are carried
out when the firing head is still separate from the burner body, during installation.
Air setting
Loosen the screw (1), move the elbow (2) so that its rear (3) coincides with the chosen stop-gate number
on the graduate stop-plate scale.
Then tighten the screw (1) with a 6mm AUen Key.
Gas setting
Loosen the screw (5), and turn the ring nut (6) so that the pointer (7) coincides with the chosen stop-gate
number on the calibrated scale (8).
Then tighten the screw (5).
9
.,'- -
--;
.
5 I
•• 7 ] Adjustment
:--, 3 range
Regulating
knob
I
7H COMBUSTION HEAD ADJUSTMENT- GAS 3 BURNER
Two separate adjustments have to be made, one for the air and one for the gas; these are carried out
when the firing head is still separate from the burner body, during installation.
Air setting _
Loosen the two screws (1) and move the internal part of the firing head (2), so that its rear edge (3) is level
with the desired set-point on the plate (4). Then retighten the screws (1).
Gas setting
Loosen the screw (5), move the ring (6) so that the pointer (7) is level with the desired set-point (8). Then
8 6 5 2
I
I stal
Umlt
stat
"I
''1
I
I
1~ 11 1 L Time J
IE I lw1
U V NJ IA I 1315
Conlactor
13 1}2 3 4 15 16 17 I
L
I-
OJ
'"
::: CF l
t-r-- W Room
slat
Supply
1 OIL relay
21
2 14
4
16 14 B . I " -
I6 96
...:
<ti
t:-- C
j--
It --
J
n '-
h 1::::
I
95
FrOSI
Sial
1- I
8~
.--
Summer
Fan l- f-
molor ~ f-Ft> OFF
r-- Winter
~~sitlon sWitch
Contactor
t-
OJ
'":::
~c::Rl W Room
OIL relay
21416 14 B L~
rr--1L::--n '-hI slat
I
I
I-+-+-+--t-.....
J"-- ~__~_______JI L _ _ _ _~
Supply 214[ 6 961----+-----i--+--++--------'
U 95
II I
8
'--!- .--
Fan I-- '-----"""'f- Summer
~~sition sWItch
SINGLE PHASE AIR HEATER WIRING DIAGRAM
Direct drive-
--.J L r-
Fan Limit
stat stat
FAN MOTOR F.LA
Model
lOa
I
I
Amps
2.5
h r1
150 I 3.4
200 5.0
300 I 6.0
r t nn
IE ILINI4 1 5 6 17 18 1 91
~ ...-~
Frost I I I Room
sta.t 240,/·1 PH· 50Hz stat
:-l r supply
h r
I IL--_------.J 1
I [
J
...----+----1
;=f- I L..-:
GS
Summer
an
motor j.-f--L.J- - - l
LI-f--.r--....... OFF
1 1 1 1
IL -nll '-------~n~ Winter Termina l bloc k
L
in Riello burner
3 Position SWitch For burner wiring refer
to Burner Wiring Diagram
l I I
J w L r----
Fan mo,~r 600 I E 5 amp
Fan mOtor 800 I B4 amp Fan Limit
Fan mOtor t 000 I 112 amp s:al stat
""l I~
1~
rE ufvlw f N
I)
[A 11 315
Con:actor
I t3
l
1 t [2 3 41 51[ 6 '1 7 1
1Q)
<II
[AIS[CIOIE[r-
U .2
..:
1
="'
OI L relay
2 14 I6 t4 B ..J"-- -~
-
Supply ~ .I 4 !6 96
95
, .' •
GS~ I ,--
Fan l-
. Summer
G'p;;sltlon sWitch
SINGLE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL
Direct drive
100
2.5
150
3.4
200
5.0
300
6.0
Summer
OFF
Wmte r Terminal blOCM
in Riello burner
3 POsll lon SWIlch
For burner wIring refer
to Burner WIring Diagram
Terminal bloCk
I
n L~
I II
1 IE
I
U I v Iw IN IA
n
I I 3 I 5 , '3
l
ItJ 2
,
31 4 I 5 11 617 j
IU
l ., I A IBI C ~D I EI
ContaClor '"
~
1
1 Supply
OI L relay
t 214161,t4
1 2 14 1 6 ~ 96
B I"--
<
.;
~
I
U [l5
(Sil-
B Fan
motor
I
O-
I--ft:>
I--
Summer
OFF
Winter
G'Pc;Sltlon sWIIch
COMMISSIONING CHECK LIST
f-
3C I Time Switch Adjustment
3D I Room Thermostat Adjustment
3F I Fan Limit Thermostat settings
Explosion Relief Door Check
3G
I
3H I Fan Inspection and rotation check
31 I Flue pipe inspection
3S Combustion Check
State percentage of Carbon Dioxide (C02) at flue outlet of heater I %
3T Set Air Pressure Switch
3U Flame Failure Lock-Out Check
3V All controls adjusted to suit customers requirements
3W Users Instructions handed over to Customer
Signature
Representative of I Date
Commissioning Organisation
Company
Leave this Commissioning Check List with user. Complete and despatch Warranty
Registration/Commissioning card and return to:
LUDLOW ROAD,
KNIGHTON,
POWYS LD7 1 LP
TELEX 35323
FAX 0547520399