Instruction manual
Contents
1. Instructions Air heaters type DXC GB 550a Page 14 17 Close the access panel once you have completed all checks The heater may now be used again 11 3 Spare parts Inshot Burners L IB3202 Ignition electrode TR DXC IB3400 am Yr Fan relay 230V 20A lonisation electrode TR DXC IK5200 IB3402 i Gas valve Flue fan IB3314 IB4516 Control Board Ignition cable GD5908 IB3929 Lock Fan motor IK6850 IP4806 Temperature sensor QR 7 Bs Fan blade DXC AG E IK4214 GD3923 Function switch GD5283 Pressure switch IK3996 Gasket set DXC GA6716 Motor Capacitor main fan IP4809 Flue fan capacitor IB4520 Propane burner kit DXC GD2380 Thermostat relay 24V IK5228 Transformer DXC GD5103 Instructions Air heaters type DXC GB 550a Page 15 17 12 Electrical diagram Gt 08OXq eni cLOc LL1 8c e1eg uouo ouelldy oyny uey ony HO kejas 1ejsouuau e 5 eee od 1109 Bunejnpojv YES s Noo me cd omy ung vs F U 9 9 OL yeysowuay Noll u i6 suoye jejisouuesu x TR 2551 LOS Jejsooq an 4 MO X u 6 oAeAseb Mol l u 6 01 ES pue 44O 0 piepuels zS S u2. parts e The big fan motor on the top of the heater the connection box will leak due to a pressure washer e The cabinet from te electronics The rubber sealing from the access door will leak with a pressure washer e Be careful with the temperature sensor in the front of the heater Do not spray too close on the wiring to the sensor The heat exchanger can be cleaned with a water pressure washer The access doors will give a good view on the tubular exchanger The water will flow out of the hater through the holes in the bottom 11 2 General maintenance To ensure the instructions below are carried out safely it is recommended having these carried out exclusively by a service technician The heater must be free of electricity during servicing Disconnect the heater from the main power Putting the function switch to 0 will not disconnect every part from the main power Perform the following activities during general maintenance e Make sure the heater has been cleaned e Grease any parts and bolts that are loosened regularly for maintenance e Check whether the wiring nuts and bolts are all properly tightened e Open the gas supply to the heater and check whether the heater and the gas hose and other connections are gas tight Finally carry out all the checks that are performed during heater installation refer to Performing checks 1 Measure the burner pressure 2 Measure combustion values 3 General heater operation
3. spigots on the heater and all flue joints must be sealed For further information regarding the flue system please contact your supplier 5 4 2 Air intake from outside C12 C32 In case of a vertical flue outlet the outlet must at least point out 0 5m above the roof surface Make sure that the air intake openings are free of any obstruction Always take the local regulations into account 5 4 3 Installation examples flue system Vertical discharge system Flue terminal IA8305 lexible 2130 Instructions Air heaters type DXC GB 550a Page 7 17 Horizontal system Flue terminal IA8312 Flexible Z130 5 5 Air intake from inside B22 Because of the pollution level inside the heated space It is not allowed to take the air from the heated space Always take the fresh air from outside trough the certified wall and roof terminals 7 Functioning of the unit 7 1 General The unit can heat as well as ventilate The mode that the heater should work on can be selected by means of the control switch on the heater 7 2 Heat demand If the thermostat indicates heat demand the following cycle will start 1 Pre purge The electronic circuit board acknowledges the heat demand and the flue booster fan will start running for 30 seconds Display print 1 2 Ignition After 30 seconds of pre purge the electrode will spark for max 5 seconds the gas valve is opened and the gas air mixture will ignite Display print 2 3 B
4. 1 amp F2 Fuses 2x 5AT U11 Status display S1 Reset service button S2 Micro switch heater no Standard all to OFF S3 Power supply thermostat when S2 no 1 to on T2 Ignition transformer connection for igniters 8 Putting into operation and adjustment 8 1 General Prior to packaging each unit is checked in detail on safety and well functioning It is among other things adjusted to the right efficiency of combustion In general the heater does not need to be adjusted after installation only a check of well functioning is necessary by a competent person The high low burner pressures can be adapted if necessary However only do this when the burner pressure turns out to be incorrect after measuring differences smaller than 0 5mbar do not need to be adjusted Never touch the adjusters injudiciously In case the installation is done following these instructions the unit can be put on Make sure the gas line is clean gastight and free from air Turn on the electrical supply with the main switch and leave the door of the heater open in order to watch the first start and so become familiar with the functioning of the unit In case of warmth demand the heater will always run for at least 4 minutes even if the warmth demand is fulfilled within this time The heater will attempt twice to start again before going on flame failure Then reset is necessary Do not forget to instruct the end user about a safe use of the heater pres
5. 3 START BY USING THE SERVICE BUTTON 9 ADJUSTING THE GAS CONTROL 10 PROBLEM SOLVING 10 1 GENERAL 11 MAINTENANCE 11 1 BASIC CLEANING THE HEATER 11 2 GENERAL MAINTENANCE 11 3 SPARE PARTS 12 ELECTRICAL DIAGRAM General U 0 Q t 0 MO AO AO OO OO ONDAMN Uu A A WW GQ UO N The DXC heaters are direct fired gas heaters with an output up to 80 kW The heat exchanger is built with S shaped tubes each having its own atmospheric burner Depending on the power of the heater there are more burners and tubes in one appliance Further the heater is provided with a sophisticated control sequence to maintain a safe and reliable operation Instructions Air heaters type DXC GB 550a Page 2 17 It is imperative that the installation and maintenance of this appliance are carried out by qualified gas engineers and strictly according to our instructions 2 1 Guarantee The guarantee is invalidated when the air heaters are not installed in accordance with this manual 3 Application restrictions Important The installation and maintenance of this air heater should be performed by an authorised competent installer in accordance with this manual This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safet
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7. INSTRUCTION MANUAL AIR HEATER TYPE DXC GB 550a THIS DOCUMENT MUST ABSOLUTELY BE READ BEFORE STARTING THE INSTALLATION INSTRUCT USER AND LEAVE THIS DOCUMENT WITH THE HEATER FOR REFERENCE Instruction manual version GB550a Heaters for GB Date 2013 Heaters for natural gas G20 and Propane 1 Introduction This installation and user manual contains the installation and users instructions for the standard and axial model of the TR series For the centrifugal duct or air curtain models additional instructions are provided in an appendix This manual is produced specifically for the gas electrical and mechanical installer Also it contains instructions how to install use and maintain the heater To assure a safe and efficient operation of this unit air heater it is absolutely necessary to apply the instructions in the manual s correctly 2 Content 1 INTRODUCTION 2 CONTENT 2 1 GUARANTEE 3 APPLICATION RESTRICTIONS 3 1 PRE CHECK 3 2 PROTECTION DEGREE 4 TECHNICAL DETAILS 4 1 DXC80 5 INSTALLATION 5 1 POSITIONING 5 2 GAS CONNECTION 5 3 ELECTRICAL CONNECTION 5 4 AIR INTAKE COMBUSTION PRODUCTS DISCHARGE 5 5 AIR INTAKE FROM INSIDE B22 7 FUNCTIONING OF THE UNIT 7 1 GENERAL 7 2 HEAT DEMAND 7 3 VENTILATION 7 4 HIGH LIMIT PROTECTION 7 5 DESCRIPTION HEATER CONTROL HC 8 PUTTING INTO OPERATION AND ADJUSTMENT 8 1 GENERAL 8 2 FUNCTION SWITCH ON THE FRONT OF THE HEATER 8
8. ash water from any direction That means no water pressure cleaner However the heat exchanger can be cleaned by means of a water pressure cleaner Do not spray with pressure water on the electrical motor or on the machine cover from the electronics Those parts can with stand water but not from a pressure cleaner Instructions Air heaters type DXC GB 550a Page 3 17 4 Technical details 4 1 DXC80 General Maximum nominal input Qn Hi 83 0 kW Minimum nominal heat input Hi 53 5 kW Efficiency max 91 5 Maximum heat output 75 9 kW Minimum heat output 47 1 kW Fan diam angle RPM Fan 1400 rpm Flue connection 130 mm 130 mm parallel CE information norm s directives the heater complies with Gas Appliance Directive 2009 142 EC Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC EN 1020 2009 non domestic gas fired air heaters EN 60335 2 102 2006 EN 60335 2 102 A1 2010 EN 55014 2 EMC NOx legislation NL KB344 1995 Safety settings Air pressure switch 0 75 mbar Limit thermostat NTC 110 C Gas G20 G25 G31 nominal gas consumption 8 8 m3 h 9 9 m3 h V h 6 6 kg h 20 mbar nominal burner pressure High Low 7 4 3 2 mbar 11 0 4 5 mbar 19 5 8 1 mbar gas pipe diameter G 3 4 G 3 4 G 3 4 nozzle diameter 6x3 7 mm 6x 3 7 mm 6x2 3 mm CO2 indication High 8 3 96 8 5 96 9 2 NOx klass 3 3 3 Electricity Rated power 900 W Thermostat connection 24 V I
9. elp of a small screwdriver Start the unit and first set the high burner pressure by turning screw external 10mm The High low coil must be energised De energise coil disconnect wire and set low burner pressure by turning screw slot for screwdriver Do not set lower than 3 mbar in order to avoid problems with inter lightning of burnerstrips Instructions Air heaters type DXC GB 550a Page 11 17 Setting screw burnerpressure low 1 1 Inlet pressure Burner High low pressure coil Attention Always check each burner pressure after any adjustment as they influence each other Always check the CO production of the heater Too much CO usually means the mixture is too rich Adjust this if necessary with the two adjusters see above 10 Problem solving 10 1 General When it turns out that the problem is not caused by the external circumstances i e no electric supply power or no gas please take the following instructions into account Please remember the built in waiting times of the heater do not react too soon and the code on the display on the electronic circuit board To simplify the investigation of the failing heater please check first e the fuses as well as the wires and plugs in the heater for possible loose contacts e Use first the service button to put the heater in run mode try later the room thermostat Volatile lock out Can only be reset by hand AA Inte
10. en 90 C and 110 C Error E1 will blink on the display The burner is switched off The fan cools the heater When the temperature is below 70 C degrees the heater will automatically restart The Error E1 will disappear 4 Temperature above 110 C Error A2 will appear on the display The burner had already stopped The fan was already cooling the heater down When the heater cooled below 70 C the heater will not restart automatically This error can only be reset manually 7 5 Description heater control HC The heater control HC controls the unit and communicates with the room thermostat Functions integrated in the heater control HC are two wire contact with room thermostat Spark ignition to burner ionisation flame guard on burner controlling the gas valve modulating the burner controlling the system fan guarding the temperature of the heat exchanger LED signals status of heater heat demand green failure red Status of heater on 8 segment display on heater control HC reset of heater service mode function Lay out print board J2 Main power connection 230V J4 Connection for gas valve and system fan J6 Connection for room thermostat appliance recognition and the status LEDs green and red Instructions Air heaters type DXC GB 550a Page 9 17 J7 Earth burner J8 Modulating coil gas valve fluebooster J9 not used J12 Connections for temperature sensors J15 lonisation selector F
11. ence of gas place of the manual gas valve the operation of the heater lock out indication and reset and about the necessary maintenance This manual must be left with the end user 8 2 Function switch on the front of the heater 0 OFF The power to the electrical components is interrupted Neutral and Live The Qo Earth connection is not interrupted The heater is OFF The internal supply wiring to the function switch is still Live 1 Auto The heater is Live and will start to burn when the thermostat connection is Q made 2 Fan The fan from te heater is running The heater will also burn when the thermostat connection is made 3 Burn The thermostat connection is manually made and the heater will start to burn Instructions Air heaters type DXC GB 550a Page 10 17 4 Reset When the heater is in Lockout Blinking A error the heater can be reset by C turning the switch shortly to the 4 position The heater will reset itself 6 3 Start by using the service button Besides operating with the function switch the heater can also be started from the service button on the print board near the display Press the service button once for 10 seconds and the unit will commence the ignition cycle 30 seconds pre purge ignition then burn The burner will then start on minimum load Display blinking gt L b By pressing the service button again the burner will go to maximum load Display print H b Pressing the ser
12. esistance 1K ohm e The heater has electrically a poor earth e The print board is defective Cause 2 e There is not enough gas pressure e The burner pressure is too low adjust the gas valve e The gas valve does not open check during ignition on 230V on the valve e Check whether the ignition electrode sparks replace cable electrode Cause 3 Heat exchanger too hot e Check if the system fan blows enough air e Check the setting of the gas valve the heater may be overloaded Cause 4 Temperature sensor on heat exchanger error e The sensor has internally 2 sensors These differ too much Measure the resistance from each sensor the resistance should be 20K at 25 en 25K at 20 If the measured values differ too much replace sensor e Rotate the sensor 1 4 turn so that the contact point is different on the sensor housing Cause 5 Too many flame failures while burning e The setting of the gas valve is not ok adjust the gas valve e The flue outlet is blocked Cause 6 The fluebooster does not run e fanis blocked or the wiring is bad e fanis defective Cause 7 The fluebooster fan runs e Check if the fan runs smoothly e Check if the fan is not polluted e Check if there is water condense in the hoses from the pressure switch Cause 8 Selection resistance error e Check the appliance recognition part replace if necessary Cause 9 Reset button error e Too many switches on reset button in a short period of time This error will d
13. has to be set to 1 e The thermostat has to be connected to the clamps 5 and 6 in the heater Any changes too these switches must be performed with the power off otherwise any changes made will not take effect Instructions Air heaters type DXC GB 550a Page 6 17 5 3 3 Fuses On the heater control HC there are two fuses See electrical wiring diagram F1 and F2 T5AJare in the power supply of the heater Replace the fuse only by a fuse of the same type The fuse F3 T0 05A protects the 24V transformer in the thermostat circuit 5 4 Air intake combustion products discharge Check for compliance with local national regulations The combined Winterwarm combustion air supply combustion gas outlet device roof terminal or wall terminal has to be used only then the installation is CE approved See installation drawings Never connect a roof terminal for condensing appliances rain can damage the heater through the discharge pipes Make sure the roof terminal is at least 0 5m above roof level Use only pipes and bends for overpressure with profiled sealing rings 5 4 1 Maximum flue length Vertical 9 meters is the maximum length between the heater and its flue outlet Horizontal 6 meters is the maximum length between the heater and the flue outlet When bends are used the pressure drop will increase and therefore a 90 bend will count as 2 metres and a 45 bend as 1 metre All flue pipes must be of the same diameter as the flue
14. isappear after some time or if the main power is disconnected for a while Cause 10 2nd STB optional switched Instructions Air heaters type DXC GB 550a Page 13 17 gt S e Heaters equipped with 2 system fans have a second temperature limiter The second limiter has switched Check the fan where this sensor is mounted e Check the wiring Heater does start but shows other problems a System fan M1 does not start Check first the functioning of this fan by connecting it to 230 Volt Check with a multi meter if the different lower tensions are present on the fan The fuse could have failed If the motor is OK the cause of the problem must be in the heater control HC as the heater control HC dictates the different voltages to the fan motor In that case replace the heater control HC 11 Maintenance It is recommended to have the heater checked and serviced by a service technician every year to guarantee reliable and safe operation Heaters used in poultry sheds must be serviced and cleaned more often due to high levels of dust and dirt in these types of spaces 11 1 Basic cleaning the heater The heater must be disconnected from electricity during servicing Disconnect the heater from the main power Putting the function switch to 0 will not disconnect every part from the main power The heater can be cleaned with water And some parts can withstand a pressure washer Do not spray with a pressure washer on the following
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16. nstructions Air heaters type DXC GB 550a Page 4 17 575 Flue 130 SA P KK AWS penes a w E Air Inlet 21 30 A gt m Gas 3 4 es S g NATANI s B 8 al 224 5 Installation 5 1 Positioning e Check and make sure that the support is solid enough Keep sufficient distance between the heater and any obstruction Take into account the possibility to open and aces the service doors of the heater for service and cleaning Pay particularly attention to any flammable materials Make sure the airflow to and from the heater is unhindered A ventilation gap is required from the top and bottom of the heater to any flammable materials Make sure that the warm air can be blown out freely There should absolutely be no possibility of materials within 5m from the front of the heater See the drawing for the safe distances e The heater is provided with 4x M10 sockets on the top and on the bottom See technical drawings e Make sure that after fitting there is no mechanical tension on any connecting gas or electric supplies e Install the heater Horizontally Attention See the application restrictions in this ma
17. nual Chapter 4 for more installation restrictions Instructions Air heaters type DXC GB 550a Page 5 17 5 2 Gas connection The gas supply line has to meet the national valid requirements and possibly the local requirements of the building inspector police or fire brigade In GB it must comply with Gas Engineers publication UP 1 and UP 2 together with BS 6891 A manual isolation valve in the supply line must be placed within reach of the heater and all gas lines must be mounted without any mechanical tension When testing the supply lines with pressures above 60 mbar this manual valve at the heater must be closed The working and standing supply pressure must be between 17mbar and 30mbar measured at the inlet pressure nipple of the gas control in the heater The burner pressure is pre adjusted high low see technical details The burner pressure can be measured on the P out measure point on the gas valve 5 2 1 Changing the gas type There is a kit available for changing the gas type from natural gas to propane or vice versa The gas nozzles have to be exchanged and the burner pressure readjusted Look into the specifications for the exact adjustments Instructions can be found in this manual 5 3 Electrical connection 5 3 1 230Vac supply The installation must comply with local and national requirements as well as IEE regulations The unit heater is delivered completely internally wired Where controls of any type are
18. rnal failure Defective print board Blinking Al No flame Within 5 sec flame then flame failure Cause 1 f No flame Cause 2 Blinking A 2 Exchanger too hot Heater stops because the temperature of the heat exchanger is A too high Cause 3 Blinking AA Sensor error Temperature sensor on heat exchanger error Cause 4 Blinking A 4 Too many flame Too many flame failures on ionization Cause 1 5 failures Blinking A5 Internal error Defective print board Blinking A6 Safety relays 2nd temperature limiter optional switched Cause 3 10 Blinking A7 Flame Flame detection when there should not be a flame Blinking Instructions Air heaters type DXC GB 550a Page 12 17 A Q Fluebooster Fluebooster does not run Cause 6 Fluebooster runs Cause 7 Blinking Non volatile lockout will disappear when the error is cleared EO Internal defect Defective print board Blinking E 1 1st temperature Heater stops because the temperature of the heat exchanger is eus safety too high When the heater is cooled down the heater will bk restart Cause 3 E2 Selection Heater recognition does not work Cause 8 x resistance Blinking E3 Selection Heater recognition does not work Cause 8 ate resistance Blinking E9 Reset error Too many switches on reset button Cause 9 Blinking Cause 1 Within 5 sec flame then flames failure e The flame is not detected Check the ignition cable and electrode cable r
19. to be added e g room thermostat the relevant wiring diagrams must be followed Never use a room thermostat to interrupt the electrical supply to the heater Make provisions to completely isolate the heater for maintenance purposes This can be an isolation switch min 3mm contact opening gap a power plug or a non switched fuse spur The wiring diagram for the heater can be found towards the end of this manual The supply is 230Vac with earth The control circuit is two wire 24V Voltage restrictions The supply is 230Vac 50Hz with earth When the supply voltage is lower than 195V and higher than 255V the correct functioning of the heater is not guarantied The tolerance on the frequency is 3Hz 5 3 2 Simple ON OFF contact with thermostat relay in heater standard configuration see schematic in this manual The heater is supplied with an internal 24V transformer in the thermostat circuit Clamps This transformer switches a relay for the on off signal in the heater for installer 230 Vac RT Every heater has to be switched by a separate ON OFF contact in N L a the control room potential free contact 1 2 3 IPE I 5 pp Do not connect more then one hater to each other under the same contact The following Standard settings on the main board in the heater have to be actual S2 S3 e The S2 micro switches on the main UUUUUUUU B board have to be set to OFF see example 12345678 e The switch S3
20. urn When the flame is detected Display print b the unit will modulate to the desired load after ca 15 seconds Depending on the given load the system fan will start modulating step less as well The air heater will always run for a minimum of 4 minutes This is to evaporate eventual condense in the discharge system 4 End of heat demand When the heat demand ends the burner will switch off and the system fan will continue to run for ca 3 minutes in order to cool the unit down Display print gt P The unit will try to ignite twice before lockout on flame fault In the case of flame failure during operation the heater will attempt one restart When the heater is in lockout you see in the display intermittent A1 On the display of the room thermostat you see failure 1 Instructions Air heaters type DXC GB 550a Page 8 17 7 3 Ventilation With the control switch on the heater the unit can be set to the ventilation mode In that way the unit will always ventilate A heat demand is also acknowledged So the heater will still burn when necessary 7 4 High limit protection The unit is equipped with a temperature sensor This NTC sensor is mounted in the front of the heater It monitors the air temperature electronically There are 4 important temperature levels detected by this sensor 1 Temperature lower than 80 C Normal functioning 2 Temperature between 80 C and 90 C Burner at minimum stage 3 Temperature betwe
21. vice button for a third time will put the unit back into normal operation depending on if there is heat demand from the room thermostat Display on the print board 0 stand by Stand by 1 Pre purge System checks and 30 sec pre purge of the fluebooster 2 Ignition The ignitionelectrode sparks 5 sec and the gas valve opens within 5 sec flame detection should occur b Burn After 15 sec stabilisation time the heater will modulate to the desired power The heater will run at least 4 minutes P Post purge The heater will cool the heat exchanger for 3 minutes and the fluebooster will post purge for 1 minute F Summer The system fan is running on the summer ventilation mode ventilation L 1 2 Service Low The heater is running on the service mode When the heater ILA runs the heater will run on minimum power Bie H 12 Service High The heater is running on the service mode When the heater LILI runs the heater will run on maximum power e e o Blinking 9 Adjusting the gas control In principle it is not necessary to adjust the gas control after putting the unit into operation In case it needs to be adjusted e g after fitting a new one this must be done only by a qualified person Only use calibrated instruments A poor adjustment can lead to overheating and or production of toxic carbon monoxide The burner pressures can be adjusted as follows Remove the cover from the gascontrol with the h
22. y 3 1 Pre check Before unpacking and installation please check i e on the data badge if the heater corresponds to the order and if it is suitable for the local present provisions gas type gas pressure electrical supply etc The installation must comply with all applicable local and national standards The installation of the air heater must be in accordance with the relevant requirements of the Gas Safety Regulations for example in GB The Institute of Gas Engineers IGE UP 1 and 2 Building Regulations and the IIE Regulations also incorporating the gas safety installation and use regulations Other national and or local regulations may apply the Local Authority Fire Officer and Insurers The competent installer must make sure the heater operates correctly and must instruct the user about the safe operation of the heater The heater should not be installed in areas containing aggressive or explosive vapors The heater can be used in poultry houses but has to be cleaned after every batch of animals or sooner if the pollution degree requires it Otherwise the guarantee will become invalidated The heater has been tested in detail on safety and correct operating settings before leaving the factory It has been adjusted for the type of gas that is stated on the data badge Should there be any doubt please contact your supplier 3 2 Protection degree The heater has a protection degree of IPX4D That means protection against spl
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