Reznor Gas Fired Air Heaters Technical data

0310DF00GBEN
GAS FIRED AIR HEATERS
TYPE
DFMA 5/.. - 10/.. - 18/.. & BC/..
Direct Gas fired flue-less appliances with
automatic electric burner control
for use as :
Type A2 : flue-less appliances with the air circulating fan downstream of the burner
Type BC/.. : are gas burners & controls modules for use in ducts and/or air handlers
These appliances meet the following EC Directives :
Dir. CE 90/396/EEG G.A.D.
Dir. CE 89/336/EEG E.M.C.
Dir. CE 73/23/EEG L.V.D.
Dir. CE 89/392/EEG M.D.*
*
does not apply to BC/.. models
This document applies to appliances designed for indoor or outdoor installation
INSTALLATION
COMMISSIONING
MAINTENANCE & SERVICING
USER INSTRUCTIONS
PLEASE READ THIS DOCUMENT CAREFULLY BEFORE COMMENCING THE INSTALLATION & LEAVE IT
WITH THE USER OR ATTACHED TO THE APPLIANCE OR GAS SERVICE METER AFTER INSTALLATION
Subject to modifications
Reznor U.K. limited – Park Farm Road – Folkestone – Kent
Tel : 01303-259141 -
Fax : 01303-850002
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11
12
13
14
15
N.B.
INDEX
Page
Principle of use and operation................................................................................................................2
General...............................................................................................................................................3
Technical data .....................................................................................................................................3
Data for BC modules ............................................................................................................................8
Installing ...........................................................................................................................................10
Air supply requirements ......................................................................................................................11
Gas connection..................................................................................................................................12
Electrical connection ..........................................................................................................................12
Commissioning ..................................................................................................................................13
Maintenance & Servicing ....................................................................................................................17
Fault finding ......................................................................................................................................19
Short parts listing ..............................................................................................................................20
Health and Safety information .............................................................................................................21
User instructions................................................................................................................................22
Annex 1 Test reports .........................................................................................................................24
If optional equipment is supplied with this appliance please refer to the additional instructions supplied with the
option.
SECTION 1 PRINCIPLE OF USE & OPERATION
1.1
1.2
Direct Gas fired Air Heaters are primarily designed for
use as make-up air appliances. Gas is injected into a
special burner that is fitted within the air stream of an
air handling appliance. A proportion of the air flowing
through the appliance is entrained into the burner to
provide a combustible air/gas mixture.
Reznor DFMA series appliances are designed for use as
permanent ventilation appliances.
6.
7.
8.
As the products of combustion are discharged directly
into the space to be heated it is essential that the rules
of application as outlined in this document are
observed.
Reznor DFMA air heaters are designed and
manufactured to comply fully with the requirements
that ensure complete safety in use is assured provided
the installation is carried out as outlined in this
document.
Reznor Direct Gas Fired Air Heaters operate on the "pull
through" principle i.e. the burner being located on the
negative pressure side of the air circulating fan. This
method ensures that a homogenous air stream is
discharged from the appliance.
Figure 1.
Legend
1.
2.
3.
4.
5.
1.3
1.4
A typical Reznor Direct Gas Fired appliance is described
in figure 1.
TYPICAL DIRECT GAS FIRED AIR HEATER LAY OUT
figure 1:
Air circulating fan
Discharge air temperature sensor
Fan motor and drive assembly
Overheat limit air temperature duct thermostat
Minimum air discharge temp. duct stat with timer
(opt. 6.08)
Wiring and controls compartment
Airflow proving differential control
Gas controls
0401DF00GBEN
9.
10.
11.
12.
13.
14.
15.
2
Dirty filter control (option 5.11)
Maximum air inlet temperature duct stat (option
6.03)
Air dampers (optional)
Weather proof fresh air intake hood (optional)
Air filter section (optional for DFMA 5 & 10)
Air filters (optional)
Airstream burner
2
SECTION 2 GENERAL
IMPORTANT NOTICE: Reznor Direct Fired Air Heaters are constructed to meet unique specifications for which they are
ordered. When tested before leaving our factory they are adjusted, fixed and sealed in their appropriate settings. Further
adjustments that may be found necessary to be carried out by the installer/commissioning engineer must respect the criteria
for such apparatus and the engineer responsible for carrying out any adjustment assumes responsibility for the continued safe
operation of the appliance when it taken into service. Sealing of a reset device must be applied.
Read the unique appliance wiring diagram, data plate and test report in conjunction with this document.
2.1
Before installation, check that the appliance
as described on the packaging label is in
accordance with the correct type and model
as specified on the data plate and complies
with your customer order.
2.2
Leave the appliance fastened to transit
packing until it is ready to be sited. This
affords protection to the cabinet and its
framework as well as providing base
clearance for trucking etc.
2.3
Please
read
this
document
commencing installation.
2.4
These instructions are only valid for the
country of use indicated on the appliance i.e.:
GB - IE. If these symbols are not shown, it is
necessary to obtain appropriate technical
instructions which will provide information
concerning the necessary modification of the
appliance for the conditions of use in the
country concerned. Such instructions may be
obtained upon request from your supplier.
2.5
2.6
before
Check that the local distribution conditions of
electricity supply, type of gas and pressure,
and adjustment of the appliance are
compatible.
Convection Air Heaters for Commercial and
Industrial Space Heating".
The Installation must also be in accordance
with the relevant requirements of "The Gas
Safety (Installation and Use regulations) and
(Amendment Regulations 1990)" and The
"Building" and "Electrical Regulations" (in GB
the IEE Regulations).
The requirements of the "Local Building
Standards Office", the premises "Insurance"
undertaking and the"Fire Office" must also be
observed.
2.7
Special attention to the air supply and
ventilation requirements contained in section
5 of this document must be given to prevent
environmental conditions occurring that may
be detrimental or even dangerous to health.
2.8
Unauthorized modification of this appliance or
departure from use in the manner for which it
was intended by the manufacturer or
installation in a manner contrary to these
instructions, may constitute a hazard and
jeopardize all warranties. Deviations should
only be carried out after formal consent has
been obtained from the manufacturer.
2.9
Ensure the environment in which the air
heater will be installed will not create a
hazard i.e. where excessive (volatile) dust,
flammable or corrosive substances and/or
vapours and combustible materials may be
present.
When installed in Great Britain the total
installation
must
comply
with
the
requirements and recommendations of British
Standard BS 6230 1991. "Installation of Gas
Fired Forced
SECTION 3. TECHNICAL DATA
3.1
3.2
The Reznor DFMA series air heaters are
manufactured in 3 basic model sizes:
DFMA 5/.., DFMA 10/.. and DFMA 18/..
The BC/.. types are complete burner and
control modules which are intended to be
used in conjunction with ducted air
distribution systems or air handlers supplied
by others.
The heat input is based upon the requirement
for raising the air volume at a reference inlet
air temperature to the design output
temperature, Tables 1 and 2 indicate the
duties available.
Due to the variety of applications for which
DFMA air heaters can be used specific data
for each model is described in quotations,
order acknowledgements and on appliance
data plates..
3.3
DFMA air heaters may under special
circumstances be used with recirculated air
from the space being heated. When used in
this manner assuming they will be dual-use
appliances i.e. re-heating/make-up air heaters
then outlet air volumes will vary due to the
difference in the inlet air temperature which
will have been designed to meet the lower
outdoor air criteria.
Where re-circulation of the already heated air
is practised then additional external controls
3
concentrations in the heated space will not be
exceeded providing the air volume figures
stated are met.
to monitor the air quality within the heated
space may be required. Refer to tables 1.2
and 5 for data of how to assess the criteria
necessary to ensure carbon dioxide (CO2)
Table 1.1
DFMA APPLIANCE DATA STANDARD SPECIFICATION MODELS
DFMA MODEL SIZE
DFMA - 5/..
Gas category 'Cat.'
DFMA - 10/..
DFMA - 18/..
II2H3+
Air supply/ combustion products evacuation type
A2
SINGLE STAGE ON/OFF BURNERS
Heat input range (Hs) 'Qn'
kW
74,0 - 148
74,0 - 296
74 - 493
Heat input range (Hi) 'Qn'
kW
67,5 - 135
67,5 - 269
67,5 - 444
High heat output range
kW
67,5 - 135
67,5 - 269
67,5 - 444
MODULATING HIGH/LOW BURNERS
Heat input range (Hs) 'Qn'
1
kW
3,7 - 148
3,7 - 296
3,7 - 493
Heat input range (Hs) 'Qn'
1
kW
3,4 - 135
3,4 - 269
3,4 - 444
kW
3,4 - 135
3,4 - 269
3,4 - 444
Heat output range
1
Gas supply
pressure 'P'2
natural gas
mbar
(GB) =17,5 (IE) = 20,0
propane
mbar
37,0
butane
mbar
28,0
Gas service connection (not supply line size)
Temperature rise <T range to maximum
Air volume3
External static pressure range
Rc :
Rc 1
Rc 12
K
2 - 55
2 - 55
2 - 55
m3/h
5000 - 9000
10 000 - 18 000
15 000 - 30 000
Pa
Electrical supply
230/240 V 1 N ~
50 Hz 380/415 V
3 N - 50 Hz
Protection grade
Indoor air heaters IP20, Outdoor air heaters IP45
kW
0,75 - 3,0
1,1 - 7,5
2,2 - 11,0
Total electric rating 4controls load
kW
0,11
0,15
0,23
" kg
182
306
488
" kg
200
320
500
5
Appliance weight gross (shipping)
2
3
4
5
380/415 V 3 N - 50 Hz
Fan motor rating
Appliance weight net
1.
50 - 300
5
Burners are assembled from modular sections of imperial length six inches (6", 0,5 feet). Each section has a maximum heat input
of 74,0 kW on gross calorific value:
DFMA 5/.. in 0,5 modules to 1,5 feet long
DFMA 10/.. in 0,5 modules to 2,5 feet long;
DFMA 18/.. in 0,5 modules to 4,0 feet long.
NOTE: The second part of the number /.. is the ? T EK as specified.
Maximum gas pressure at inlet to appliance = 50,0 mbar
Natural gas G 20, calorific heating value 10,48 kWh/m3 on Hs @ 15 EC & 1013 mbar
Propane G 31, calorific heating value 14,0 kWh/kg.
Butane G 30, calorific heating value 13,7 kWh/kg
Total electrical rating equals motor load rating plus controls load
Approximate dependant on motor size burner length and options fitted
4
Table 1.2 : RANGE RATING OF DFMA AIR HEATERS
BURNER LENGTH
Q = ft
MAXIMUM HEAT
INPUT kW
@ GCV
MINIMUM HEAT
INPUT kW
@ GCV
1
MINIMUM AIR
VOLUME per kW
HEAT INPUT m3/h
DFMA MAXIMUM
AIRFLOW m3/h
DFMA 5..
0,5
74
3,7
60,8
9 000
DFMA 5..
1,0 or 1,5
148
7,4
60,8
9 000
DFMA 10..
0,5
74
3,7
60,8
18 000
DFMA 10..
1,0
148
7,4
60,8
18 000
DFMA 10..
1,5
222
11,1
60,8
18 000
DFMA 10..
2,0 or 2,5
296
14,8
60,8
18 000
DFMA 18..
0,5
74
3,7
60,8
30 000
DFMA 18..
1,0
148
7,4
60,8
30 000
DFMA 18..
1,5
222
11,1
60,8
30 000
DFMA 18..
2,0
296
14,8
60,8
30 000
DFMA 18..
2,5
370
18,5
60,8
30 000
DFMA 18..
3,0
444
22,2
60,8
30 000
DFMA 18..
3,5 or 4,0
518
25,9
60,8
30 000
MODEL TYPE
NOTE: 1 Necessary to limit the volume of carbon dioxide (CO2) that enters the building as a result of combustion.
Table 2 : PERFORMANCE GRAPH - TEMPERATURE RISE RE MAXIMUM AIR VOLUME for MODEL SIZE
Legend :
<T
= Temperature rise
GCV = Gross calorific value of the gas (e.g. wet)
P
= Heat output in Watts
Cp
= Specific heat of air taken as 0.3423
W = Power in Watts
V = Air volume
K = Temperature Kelvin
5
Figure 2 : DIMENSIONS MODEL DFMA - 5
SIDE ELEVATION STANDARD HAND CONTROLS SIDE
PLAN VIEW
END VIEW AIR
OUTLET
Figure 3 : DIMENSIONS MODEL DFMA - 10
SIDE ELEVATION STANDARD HAND CONTROLS SIDE
PLAN VIEW
END VIEW AIR OUTLET
6
Figure 4 : DIMENSIONS MODEL DFMA - 18
SIDE ELEVATION STANDARD HAND CONTROLS SIDE
PLAN VIEW
END VIEW AIR OUTLET
7
Table 3. Maximum load ratings for 4 pole motors: Single phase - DFMA - 5
Motor rating
kW
Phase
~
1
1
Voltage
V
230
230
~A
4,0
4.7
Load rating " 5%
0,55
0,75
Starting mode
Direct on line
Table 4. Maximum load ratings for 4 pole motors: Three phase - DFMA - 5 - 10 - 18
Motor rating
kW
0,55
0,75
1,1
Phase
~
3
3
3
3
3
3
3
3
3
3
3
3
Voltage
V
230
400
230
400
230
400
230
400
230
400
230
400
Load rating " 5%
A
2,4
1,4
3,1
1,8
4,5
2,6
5,0
2,9
8,3
4,8
11,5
6,6
Starting mode
1,5
2,2
3,0
Direct on line
Table 4. concluded
Motor rating
kW
4,0
Phase
~
3
3
3
Voltage
V
230
400
230
400
230
400
230
400
230
400
15,3
8,8
20
11,5
26,9
15,5
36,5
21,0
50,4
29,0
Load rating " 5%
Starting mode
A
5,5
7,5
3
3
11,0
3
3
15,0
3
3
3
L/Y
SECTION 4 DATA FOR BC MODULES
4.1 BC../.. Direct Gas Fired Modules comprise air
stream burners mounted in a profile plate (panel)
connected to a gas manifold and controls train.
They are for installing as A2 type appliances i.e.
burner on the negative pressure side of the fan
within duct systems or for installing within air
handlers supplied by others.
When installing these modules it is necessary that
the completed installation including the direct fired
heating module complies with the total
requirements of PrEN 525 1996 (scheduled to be
published as EN 525../1996).
NOTE: It is the responsibility of the installer of BC
modules to ensure that the total installation complies
with the requirements of Dir CE 89/392/EEC
Machinery Directive and that components included in
the installation i.e. motors, thermostats, etc. meet the
requirements of CE 89/336/EEC Electro Magnetic
Compatibility and CE 73/23 Low Voltage Directives.
4.2 BC Direct Gas Fired modules are designated by the
letters BC (burner/control) with digits following
indicating the maximum heat input rating in kW
gross calorific value of the gas and the burner
length (in feet imperial).
e.g. BC 148/1,0 is a module of 148 kW heat input
from 1 foot of airstream burner.
4.3 Table 5 indicates the possibilities for modules with
burner lengths from 0,5 to 4,0 feet. It should be
noted that this is not the maximum size that can
be manufactured. For larger sizes extrapolation of
the criteria contained in the table is necessary.
Table 5. BC MODULES possible configurations
BC MODEL TYPE
MAXIMUM HEAT
INPUT kW @ GCV1
BURNER LENGTH
FEET IMPERIAL
Dim "X" fig. 5
MINIMUM HEAT
INPUT kW GCV
MINIMUM AIRFLOW
per kW HEAT INPUT
per m3/h
DFMA BC 25/0,16
25
0,16
1,23
60,8
DFMA BC 74/0,5
74
0,5
3,7
60,8
DFMA BC 148/1,0
148
1,0
7,4
60,8
DFMA BC 222/1,5
222
1,5
11,1
60,8
DFMA BC 296/2,0
296
2,0
14,8
60,8
DFMA BC 370/2,5
370
2,5
18,5
60,8
DFMA BC 444/3,0
444
3,0
22,2
60,8
DFMA BC 518/3,5
518
3,5
25,9
60,8
DFMA BC 592/4,0
592
4,0
29,6
60,8
1
Necessary to limit the volume of carbon dioxide (CO2) that enters the building as a result of combustion
8
4.4 Profile openings for burners must be designed to
provide an airstream velocity across the burner of
15m/s. When calculating the area for the profile
opening a distance of 50 mm must be allowed at
either end of the burner.
4.6 Profile opening must be sized in accordance with
the criteria stated below. It is usual to add 50 mm
to the resultant height of the profile to allow for
adjustment of the air velocity across the burner
when the system is commissioned.
4.5 The design temperature rise of the air must not
exceed 55 EK.
4.7 Refer to figures 5 and 13 for profile design.
CALCULATING BURNER PROFILE OPENINGS
Example
Instruction
1.
2.
Assumed burner length = 3,0 ft
Calculate total burner area:
Overall length "X" of burner x burner area per foot
(area per foot = 0,65 ft2)
"X" as figure 5
3,0 ft X 0,65 ft = 1,95 ft2
Convert to m2 = X 0,0929
1,95 ft2 X 0,0929 = 0,181 m2
Calculate the net profile area:
30 000 m3/h ) 3 600 = 8,333 m3/s
Total air volume m3 /s
Required air velocity Vo
3.
8,333 m3 /s
= 0,555 m2
15 m3 /s
NOTE: Use constant Vo 15 m/s
Calculate the gross profile area:
Burner area + net profile area combined
0,181 m2 + 0,555 m2 = 0,736 m2
4.
Calculate the length of the profile opening:
Burner length "X" + 50 mm each end
5.
Calculate the height of the profile:
3,0 feet = " 914 mm
914 mm + 100 mm = 1014 mm (1,014 m)
0,736 m2
= 0,726 m =726mm+ 50mm =776mm
1,014 m
Gross profile area
Y=
Length
"Y" as figure 5
Add 50mm for profile adjustment when commissioning
_______________________________________________________
4.7 Figure 5 shows a typical duct or air handler
section. The dimensions A, B & C are those of the
client specification, it should be remembered that
these dimensions must allow for the burner
installation sizes calculated as indicated above.
When the direct fired heating module
manufactured it will be set and sealed in
is
accordance with the criteria specified by the
client. Refer to the instructions for the Reznor
DFMA series air heaters contained in this
document for adjustments etc.
The areas in which the burners are installed,
must remain free from any obstructions i.e fans,
dampers,filters,etc.
9
ventilated at both high and low level so as to
prevent a build-up of unburnt gas and overheating
of the controls. Such openings shall have a
minimum area of at least 2% of the area of the
largest plain surface of the compartment. The
openings shall be sized so that a of the area is
open at the top of the compartment and b at the
bottom of the compartment. All compartment
openings must not must not allow the insertion of
a ball of 16 mm diameter i.e. constructed to
conform with IP 20
If closure dampers are incorporated within the air
circuit they must be electrically interfaced with
the burner controls so as to prevent start-up of
the burner when not in their fully open position.
If discharge air outlet louvres are fitted, the blades
shall be provided with a stop, so as to prevent
closure beyond 45E. Closure positioning for
appliance transportation purposes shall not be
possible whilst the appliance is operational.
Appliances and systems that are installed in
excess of 1,8 m above floor level and those that
are intended to be installed outdoors shall have all
removable panels that are intended to be used for
service and maintenance access, secured by
permanently fitted restraining straps to prevent
their falling when used. It is recommended that
substantial earth bonding straps are used for this
purpose. Hinged panels are deemed to satisfy this
requirement.
4.9 For DFMA air heaters and duct systems designed
to be installed outdoors, all air inlets including
those mentioned in 4.7 above must be sited so
that the lowest edge of the opening will be at
least 500 mm above the level of any deck or floor.
Ventilation openings shall be protected so that
they will not become obstructed e.g. by leaves,
storage of material, etc. Notices should be
provided by the installer and posted as appropriate
to ensure that ventilation openings remain clear at
all times.
4.8 When burner controls are installed in a separate
compartment, the compartment must be
Figure 5 : DESIGN CRITERIA FOR BC APPLICATIONS
Legend :
1. Inlet protection grille to IP 20
2. Airstream burner
3. Adjustable and sealable burner profile
4. Burner gas manifold
5.
6.
7.
Burner inspection viewing port
Separated compartment for gas & electrical
controls
Optional protection grille to IP 20 to prevent
access in front of burner
SECTION 5 INSTALLING
OUTDOOR APPLIANCES:
5.1 If the DFMA air heater is to be installed outdoors
ensure that it has been supplied for this
application.
When the appliance is to be installed outdoors and
the site is accessible to the public then
appropriate protection in the form of a fence must
be provided. The premises security may be
jeopardized by the installation of outdoor air
heating appliances. Consideration should be given
to the possibility of un-authorised entry to the
premises being made via appliance and duct work
access panels etc.
10
ALL APPLIANCES
5.2 Check that the air supply and ventilation
requirements will be met as outlined in section 6
of this document.
5.3 The DFMA air heater may be installed in a
suspended manner using the suspension points
provided on the appliance. These air heaters may
be base mounted. Ensure that the air heater is
secured to any base mounting arrangement.
Ensure that the structural elements of the building
are adequate to carry the weight of the appliance
and its ancillary components i.e. the air
distribution duct work. If suspended the appliance
should remain rigid so as not to impose a strain on
the services connected to the appliance.
5.4 Ensure that sufficient space around the air heater
is maintained for servicing and that the appliance
is not sited where it may suffer from damage by,
e.g. fork lift trucks.
5.5 The appliance and its air distribution duct work
should be insulated and protected by a waterproof
membrane where it is exposed to outdoor
conditions.
Duct work should be designed so that minimum
restriction at the air outlet (and if applicable the air
inlet) on the appliance exists. It is important that
an even airflow through the air heater is
maintained to ensure good combustion takes
place.
5.6 Air inlets to the building must be protected so as
to prevent the ingress of birds, leaves, etc.
Warning notices should be displayed advising
about blocking air inlets to the air heaters.
SECTION 6 AIR SUPPLY for COMBUSTION & VENTILATION
6.1 Reznor DFMA air heaters mix the products of
combustion with fresh air entering the appliance and
discharge the mixture directly into the space to be
heated. To maintain a safe and healthy environment it
is therefore, essential that sufficient fresh air is
provided in accordance with the amounts advised in
this document.
Normally DFMA air heaters are used for make-up air
purposes the extract volume of the air being matched
by the inlet air volume of the air heater. Recirculation
of heated air may be practised provided that the
appropriate volume of fresh air to ensure a safe level of
CO2 is maintained. The air supply requirement can be
calculated from the data provided in this section.
Power air extract equipment i.e. spray booths, etc.
must be electrically interlocked with the air heater. If
varying proportions of fresh air/recirculated air are
possible
by
control
of
dampers
in
the
heating/ventilating system these must also be
interlocked to ensure that an unsafe condition cannot
be achieved.
6.2 Unless specified to the contrary by users or relevant
authorities, the allowable limits of carbon dioxide (CO2)
in the atmosphere as result of direct gas fired are
heating must not exceed 0,28% (V/V) or 2800 ppm /
(2800/10-6). This figure when met ensures that the
other gases contained in the products of combustion
are maintained within safe limits.
6.3 Where recirculation of air is practised it should be
limited in proportion to the total air volume passing
through the appliance and entrained downstream of
the burner.
limit the CO2 limit indicated in table 5.
The figure of 60,8 m3 of fresh air per KW of heat input
at gross calorific value must be maintained as a
minimum requirement for all Reznor DFMA air heaters.
6.4 In the event that the design dictates deviation from the
requirements of clause 6.3 above. Reznor engineering
department must be consulted for approval.
6.5 Reznor recommend that in cases where recirculation is
required then only recirculation air volumes in excess
of the volumes required as stated in clause 6.3 may be
considered. If recirculation is practised that zones
where warm air is discharged are provided with CO2
constant monitoring devices electrically interfaced with
the appliance burner safety controls.
6.6 Ventilation including BC Models:
Ventilation of the burner compartment must be
provided by the inclusion of openings sized in
accordance with mandatory requirements.
For DFMA air heaters and duct systems designed to be
installed outdoors, all air inlets including those for
ventilation of the burner controls compartment above
must be sited so that the lowest edge of the opening
will be at least 500 mm above the level of any deck or
floor.
Ventilation openings shall be protected so that they
will not become obstructed e.g. by leaves, storage of
material, etc. Notices should be provided by the
installer and posted as appropriate to ensure that
ventilation openings remain clear at all times.
On no account should the volume of recirculation air
reduce the volume of fresh air below that required to
11
SECTION 7 GAS CONNECTION
7.1 Connection to a gas service may only be carried by
suitably qualified persons. The gas installation must
comply with the rules in force using materials
appropriate for gas service installations.
Fig. 6
GAS CONNECTION DETAIL
7.2 Check that the gas category is in accordance with the
data described on the air heater.
7.3 An adequate gas supply sized to provide the dynamic
pressure for the volume required by the direct fired air
heater(s) is essential to maintain the nominal heat
input.
7.4 For applications where pressures higher than those
normally supplied for the appropriate gas a reducing
governor is available as an option.
7.5 A 90E action gas service tap and, to facilitate
servicing, a disconnect union fitting must be provided
adjacent to the appliance, see figure 6.
7.6 Ensure that a gas service includes a filter and has been
tested and purged in accordance with prescribed
practice prior to commissioning and taking the air
heater into service.
If there is doubt about the adequacy of a gas filter,
one should be fitted at the gas inlet to the appliance.
WARNING: NEVER use a FLAME to test for GAS
Soundness !!!
SECTION 8 ELECTRICAL CONNECTION
8.1 The Electrical installation may only be carried out by
suitably qualified persons observing the rules in force.
8.2 Check that the electrical specification is in accordance
with the specified data on the air heater. A unique
appliance wiring diagram is supplied as a separate
document attached to this one, plus an additional copy
is attached to the air heater.
8.3 These appliances must be earthed.
8.4 A separate electrical isolator for each heater must be
provided adjacent to the appliance in a position so that
it is visible to any person working on the appliance.
The isolator must have a contact separation of at least
3.0 mm on all poles. The isolator must be of the key
operable type so that electrical safety for those
persons working on the appliance is assured.
8.5 Ancillary controls are required to provide timed heat
cycles, if appropriate, room comfort temperature level,
frost protection, override air circulation etc. These are
not included with the appliance and should be ordered
separately.
8.6 Reznor direct fired air heaters are supplied equipped
with a fuse included for protection of the heater
burner controls circuit. it is the responsibility of the
installer to provide fuses as appropriate for external
control/s circuits.
8.7 When planning DFMA controls circuits be sure to take
into account any interface circuits that may be
required between the gas burner and e.g. air dampers,
extract fans,etc.
8.8 For BC models ensure that motors and controls fitted
by others meet the requirements of 4.1 of this
document.
IMPORTANT NOTE: DFMA AIR HEATERS THAT ARE
APPLIED AS CONTINUOUS OPERATING APPLIANCES, i.e.
24 HOURS EACH DAY MUST HAVE A DEVICE (TIME
SWITCH) INCLUDED IN THE EXTERNAL CONTROL
SYSTEM TO SWITCH OFF THE APPLIANCE BRIEFLY ONCE
EVERY 24 HOURS. THIS IS NECESSARY TO TEST THE
INTEGRITY OF THE AIR FLOW PROVING SAFETY DEVICE.
12
SECTION 9 COMMISSIONING,LIGHTING AND OPERATION
COMMISSIONING
9.1
Normally Reznor Direct Fired air heaters do not
require commissioning. Final testing after
production ensures that: If installation has been
carried out strictly in accordance with this
document and air circulation ducting etc. has been
sized correctly so that the system design
parameters are met, the appliance is ready to be
taken into service.
9.2
Checks to ensure;
- earth continuity
- resistance to earth
- phase supply to correct terminals
- current rating and fuse value
- correct supply gas pressure
- correct burner gas pressure
- satisfactory & smooth ignition
- that fans rotate in the correct direction
- that any air discharge louvres cannot be closed
beyond 45E when the air heater has been taken
into service
9.3
In addition to the above requirements checks to
ensure that the fan performance and motor load
factors are correct for the application and in
accordance with the appliance data plate.
9.4.2
Adjusting the fan speed can be carried out by
altering the diameter of the adjustable drive pulley.
- Loosen the belt tension adjustment device and
remove the drive belt/s.
- Refer to figure 7 and note that the outer section
of the drive pulley is secured by a hexagon
socket grub screw to a flat on the pulley hub,
this is positioned by loosening the grub screw
sufficiently to enable the pulley to be either
opened or closed by turning it on the thread on
which it is engaged.
- It should be noted that one complete turn of the
pulley half is equal to approximately 8% of the
fan speed. Closing the pulley increases the
speed and opening decreases the speed.
- after making speed adjustments tension belt in
accordance with the dimensions given in figure
7 and check pulley alignment to ensure the belt
runs correctly.
N.B. Always ensure that the pulley is tightened
onto a flat of the hub before switching on the fan,
even when testing a reset condition.
Figure 7 Pulley & belt adjustment
Deviations to air flow rate from that which the air
heater was originally set will affect the burner
performance. if adjustments are necessary note
section 9.4 below.
9.4
Drives general and adjustments
9.4.1
Before commencing work on the fan assembly:
- Set external controls to off or their lowest
setting.
- Turn OFF the gas supply to the air heater.
- Switch OFF the electricity supply to the air
heater. Lock the appliance electrical isolator in
the OFF position.
- Open the service access panel and if
appropriate, remove protection guards and carry
out adjustments as required.
- Before placing the appliance back into service or
switching the fan on ensure that all access
panels and if appropriate, protection guards are
replaced and secured.
N.B. Rotational speed checks should be carried out
using an infra red tachometer or stroboscope.
After any adjustment change the data described on
the appliance test report accompanying this
document.
9.5
BURNER PROFILE ADJUSTMENT
DFMA air heaters are fitted with profile adjustment
plates these will have been set and sealed for the
air flow duty specified.
13
In the event that the air flow duty is changed from
the design rate when the appliance is
commissioned it will be necessary to re-adjust the
plates to maintain the necessary design air velocity
across the burner, NOTE; THIS IS MOST
IMPORTANT. The design velocity at 15 EC
1013,25 mbar must be set to " 15 m/s. If
adjustment is made, the new setting position
should be marked and sealed and the new
dimensions recorded on the test report
accompanying this document.
9.6
electronic flame relay will switch off and lockout
will occur. This will cause the signal lamp to glow
within the reset switch on the appliance and/or a
remote control if fitted). After about 10 seconds
the reset button on the appliance or the remote
control can be operated in order to reset the
appliance.
9.7.5
LIGHTING
-
Ensure that air discharge louvres and/or grilles
are set to an open position;
Check if fire dampers are fitted in the duct
system these are open and secured;
Ensure that inlet air dampers if fitted are open
and in the correct setting mode;
Turn ON the gas supply to the air heater;
Switch ON the electricity supply to the air
heater;
Set appliance controls to an ON setting;
If fitted ensure that a time control is at an ON
setting;
NOTE: The gas burner will only operate when
the air circulating fan is running.
-
If reset button on heater and/or on remote
control (if fitted) glows, press reset button.
Heater should now light automatically within
2 minutes.
For a new installation or if the appliance has
been turned off for an extended period then
up to 3 attempts to light the air heater may
be necessary. If the heater still does not light,
consult the fault finding guide section 11.
Flame failure protection is by the ionisation
principle i.e. the ability of a suitable flame to pass
an electrical current between the igniter and the
earthed burner assembly. To check the flame
current is adequate it is necessary to connect a
DC micro ammeter between the flame sensor and
it's lead wire connection. Ionisation current should
be;
" 0,5 µA. of the value stated in the Reznor
appliance test report accompanying this document.
Note: The circuit carries mains voltage when
energised.
9.7.6
In the event of the air volume falling below an
adequate or safe level i.e. due to blocked filters,
broken fan, etc., safety shut down of the burner
and/or burner lock out will occur. Dependant on
the control type fitted, resetting of the burner
control may be necessary before the appliance can
be placed back into service.
9.7.7
If the burner flame is extinguished for any reason
during a run cycle safety shut down will take
place. Manual intervention to reset may be
necessary to put the air heater back into service.
9.7.8
In the event of overheating for any reason,
thermally a activated fail safe overheat control
operates to switch off the burner.
9.7.9
To switch off the air heater for a short period;
a/ switch OFF the appliance control
To relight, switch ON the appliance control
9.7
OPERATION
9.7.1
At the dictates of the external controls, an
electrical circuit is made and air circulation fan
runs.
9.7.2
Provided adequate air flow is proved, the fan alone
will run for a pre-purge period to ensure that the
appliance and the air distribution system are
adequately ventilated.
9.7.3
Refer to figure 8.
For prolonged period;
a/ switch OFF the appliance control;
b/ turn gas supply to the appliance OFF;
c/ switch OFF electricity supply to the air heater.
To relight follow lighting instructions.
9.7.10 The gas service tap must only be operated in
emergencies, for servicing or prolonged periods
of shutdown of the air heater.
DFMA air heaters light automatically by a spark
ignition device which ignites a start gas burner at
the dictates of an automatic sequenced electronic
burner control.
At the end of the pre-purge period the start gas
valve(s) will open and the ignition burner will be lit.
Provided a satisfactory flame has been established,
the main burner will light after an ignition burner
proving period.
9.7.4
If the burner has not lit within the proving time, the
14
9.8
9.8.3
BURNER MODULATION
Connect a manometer to the burner gas pressure
test point, and then proceed as follows;
Most Reznor DFMA air heaters are fitted with
modulating burner controls. This feature enables
the burner to modulate at the dictates of the
external controls between the maximum high fire
rate and the low pre-set point. The minimum low
rate achievable is 20 : 1 or 5 % of the high fire
rate.
High rate adjustment;
NOTE: When carrying out adjustments
ensure that the appliance dynamic gas inlet
pressure is adequate.
The standard system fitted to provide modulation
is a "Maxitrol" system. Comprising the components
necessary for burner modulation control, duct
and/or room temperature sensors, signal amplifier
and modulating gas pressure regulator known as
type M or MR. The MR gas pressure regulators are
powered by a variable 24V DC voltage. Maximum
outlet pressure occurs between 15 - 20 V DC
(high fire). Minimum outlet pressure occurs at 0 - 5
volts DC.
The power signal is obtained from a Maxitrol
system A1014 duct sensing or A1044 room
sensing amplifier which is an integral control within
the appliance or, if preferred a signal from another
control system by other than Reznor designed to
provide the required sensors and controlling
voltages.
1. Disconnect the wires to from terminal 4 on the
A 1014 or terminal 3 on the 1044 amplifier or the
low fire control circuit (see appropriate wiring
diagram). Ensure that between 15 and 20 volts
remains on the regulator. This causes the regulator
to provide continuous high rate.
2. Adjust pressure regulator to obtain the required
manifold burner pressure clockwise rotation
increases pressure (see fig. 8).
3.Re-connect the wire to restore the amplified
control.
Low rate adjustment;
1. Disconnect one wire from the terminal on the M
611 regulator, this will cause the regulator to
provide continuous low rate;
9.8.1. M 611 Modulating Regulator
The M 611 gas pressure regulator is fitted
downstream of any other gas pressure control. It
should be noted that adjustment of any upstream
pressure regulator will be necessary to compensate
for the pressure loss across the M 611 regulator.
The M 611 controls the gas supply when the
safety and main gas valves are open. At zero volts
the M 611 is in the normally low pre-set by-pass
position.
2. Remove cap (figure 8, A) and loosen the screw,
turn adjusting screw (B) (use a c" hexagon
wrench) to desired low rate setting, (clockwise
reduces minimum flow rate) NOTE: there are two
adjustment positions either side of the regulator;
3. Replace control wire.
9.8.4
MR 212 Modulating Regulator
the
The MR 212 regulator operates in a similar manner
to the M 611, (see figure 9).
The maximum gas rate is controlled by the main
gas pressure regulator (see figure 8).
When the main burner gas valves open the MR 212
controls the gas flow to the main burner. The MR
212 is in a normally low set point position.
The by-pass is adjustable for setting
low/minimum gas rate (see figure 8).
Variable voltage applied to the M 611 causes a
magnetic core to move thus actuating a diaphragm
allowing gas to flow at a controlled rate to the
main burner. At the maximum control voltage the
burner will be at it's highest set rate (high fire of
the burner).
9.8.2
M 611 Adjustments:
Extreme situations;
LOW RATE: When there is no voltage to the
611 gas flow will only be via the by-pass;
M
HIGH RATE: When the M 611 is powered the
maximum gas flow rate is controlled by the main
gas regulator.
When no gas pressure is present in the upper
chamber above a diaphragm a spring closes down
the gas regulator into the pre-set low position via a
by-pass the rate of which is controlled by an
adjustable in-built separate pressure regulator. This
is the minimum or low rate condition.
When modulating voltage is applied, gas pressure
in the upper chamber of the MR 212 overcomes
the pressure of the closing spring causing the
regulator to open in a controlled manner. The more
the modulator opens the greater the pressure in the
upper chamber thus the higher the gas flow rate.
The high gas rate is controlled by the integral main
gas pressure regulator.
NOTE: Actuation of the core occurs between 5 and
15 volts.
15
9.8.5
Extreme situations:
Low fire gas rate is controlled by the by-pass
setting;
2. Remove cap, loosen the screw (C) and turn
adjusting screw (D) to required low rate
setting,(clockwise rotation reduces the low rate)
High fire gas rate is controlled by the voltage
applied to the MR 212 up to the maximum set
point which is dictated by the integral main gas
pressure regulator.
3. Tighten screw (C), replace control wire.
MR 212 Adjustments:
Connect a manometer to the burner gas pressure
test point, and then proceed as follows;
NOTE: When carrying out adjustments ensure that
the appliance dynamic gas inlet pressure is
adequate.
High rate adjustment;
1. Disconnect the wires to terminal 4 on the A
1014 amplifier or terminal 3 on the A 1044
amplifier, or remove the low fire amplified current
circuit, (see appropriate wiring diagram). Ensure
that between 15 and 20 V remains on the
regulator. This causes the regulator to provide
continuous high rate;
2. Remove the sealing cap (figure 9 key A) and
turn the regulator adjusting screw to obtain the
required manifold burner pressure. Clockwise
rotation increases pressure;
3. Re-connect the wire to restore the amplified
current.
Low rate adjustment;
1. Disconnect wire from the terminal on the
MR 212 gas regulator, this will cause the regulator
to provide continuous low rate;
9.9
DFMA BURNER PRESSURES
The operating burner pressure of type A DFMA air
heaters is influenced by the negative static
pressure of the air passing through the appliance,
this negative pressure causes a vacuum on the gas
manifold which is open to the airstream via the
burner gas ports. The heat input is therefore, the
pressure recorded on the gauge whilst the air
circulating fan is running at it's pre-set condition.
This reading is the total gas pressure and is the
sum of the negative gas pressure and the positive
gas pressure to meet the required pressure setting
i.e. for high rate.
When in low rate setting the gas manifold pressure
will read negative.
To check the burner pressure setting:
1. Loosen the test points screws and then connect
a manometer to both the air stream reference
and burner manifold test points. Read off the
pressure which is the total burner pressure.
2. When test is complete, remove manometer and
close securely screws on test points.
IMPORTANT
When commissioning is complete ensure that the
commissioning report, annex 1, pages 25 & 26 of this
document this and supplied with the air heater is
completed in accordance with the instructions described
thereon.
Figure 8 : M 611 Modulating Gas Pressure Regulator
HIGH RATE ADJUSTMENT
9
16
Figure 9 : MR 212 Modulating Gas Pressure Regulator
Legend:
1. High rate main burner adjustment
2. Low rate adjustment
SECTION 10 MAINTENANCE & SERVICING
10.1 General :
Servicing and maintenance work may only be
carried out by appropriately qualified persons.
10.2 Caution:
Inadvertent substitution or replacement of
components similar to those specified or
replacement in a manner contrary to the method
described in this document could constitute a
hazard.
10.3 Before commencing service work:
Switch OFF the air heaters at the external controls,
WAIT until the appliance fan has stopped and then;
Lock OFF (see section 8) the electricity supply to
the air heater at the isolator provided;
Turn OFF the gas supply to the air heater at the
appliance isolation tap provided.
10.4 Generally clean the appliance thoroughly whilst
checking the items listed below.
10.5 Features to check when carrying out service:
1) Security of appliance installation including;
suspension devices;
ductwork;
gas service;
electrical installation including external
controls;
2) Air heater cabinet; check for damage, check
access panels and ensue that fastening devices
are operable, check for air leakage around duct
work joints, check condition of damper blades if
fitted.
3) Air handler: Check security of drive pulleys,
check drive belts, ensure that fan bearings are
clean and look for signs of wear by checking
end float on blower shaft/s, check fastening of
motor and condition of electrical connections to
it including contactor and overload if applicable.
4) Air dampers: If dampers are fitted check their
operation and that linkages are secure and that
travel of the dampers is complete in respect of
their purpose.
5) Gas burner: Inspect gas burner and look for
signs of corrosion and distortion that may
indicate over firing or incorrect air flow across
the burner. Check the condition of the ignition
and sensor electrodes and their wire
connections, look for signs of damaged ceramic
insulators. Check gas outlet ports on both the
ignition burner and the min burner, clean ports
with a soft brush and an air line.
6) The correct location of the adjustable burner
profile plates is marked on the appliance during
commissioning, ensure that the adjustment
position is correct and that the plates are
securely set and sealed in the appropriate
position.
7) Burner controls, valves, pressure regulators,
etc. Check for gas leaks, faulty wire
connections and general condition of the
components.
10.6 Supplementary controls:
Airflow proving switches, automatic burner control,
thermal overheat devices, air temperature
thermostats, electrical wiring, etc.:
Inspect to determine operation, settings, and
condition of these devices.
10.7 Upon completion of service work re-commission
the appliance in accordance with section 9 of this
document. Report any anomalies to the occupier or
their representative.
17
Figure 10 : TYPICAL DIRECT FIRED AIR HEATER BURNER CONTROLS M 611 MODULATION (heat input < 180kW)
Legend :
A. Inlet gas tap
B. Main burner gas tap
C. Inlet gas pressure test point
D. Reference pressure test point P1 combustion chamber
Burner manifold gas pressure test point P2
E.
Gas pressure regulator
G. Safety gas valve
H.
I.
K.
L.
M.
Main (control) gas valve
Ignition burner gas valve
Modulating pressure regulator M 611
High gas pressure cut-off switch (option 6.34)
Low gas pressure cut-off switch (option 6.33)
I.B. Ignition burner
M.B. Main burner
Figure 11 : TYPICAL DIRECT FIRED BURNER CONTROLS ARRANGEMENT MR 212 MODULATION (heat input > 180kW)
Legend
A. Inlet gas tap
B. Main burner gas tap
C. Inlet gas pressure test point
D. Reference pressure test point P1 combustion chamber
Burner manifold gas pressure test point P2
E.
Main gas pressure regulator
F
Ignition burner pressure regulator
G. Safety gas valve
H. Main burner (control) gas valve
I.
Ignition burner gas valve
K. Modulating pressure regulator MR 212
L.
High gas pressure cut-off switch (option 6.34)
M. Low gas pressure cut-off switch (option 6.33)
I.B. Ignition burner
M.B. Main burner
18
Figure 12. Ignition burner detail
Figure 13. Burner Profile Adjustment
SECTION 11 FAULT FINDING
11.1 Air heater will not start;
-
Read the commissioning instructions "How it
works";
Ensure that the electricity supply is switched
ON;
Ensure that the gas supply to the appliance is
turned ON;
Check that all external controls are set in an
appliance on mode;
NOTE: The burner will not operate unless the air
circulation fan is running!
-
Check fan motor is not locked out on
overload;
Interface with other air handling apparatus
i.e. air extraction fans or their control circuits
faulty, Check if appropriate.
11.2 Air circulation fan running burner will not fire:
-
-
Ensure that the inlet gas pressure to the
appliance is not too low
Burner controls in lock-out mode, Reset;
Thermal over-heat (limit) control in lock-out
mode, Reset;
Low air flow , blocked filter , wrong fan
speed, Check;
Air flow proving switch broken, set
incorrectly, faulty wiring connection, Check;
Faulty automatic burner control, Check;
-
DFMAs over 180 kW heat input: Valves with
proof of closure device: Not switched;
Faulty ignition burner gas valve or electrical
connection to the valve, Check;
NO SPARK !!: Faulty ignition transformer or
ignition lead connection, ignition current short
circuiting ! break in ignition lead;
Controls electrical circuit fault, Check circuit
in logical manner, against appliance wiring
diagram.
11.3 Ignition burner lights and goes out main burner will
not light;
-
11.4
Insufficient ionisation current, See section
9.7.5
Valves with proof of closure devices: Valve
not proven in closed position;
Burner lights high or low rate not achieved:
-
See section 9.3.3 & 9.3.4;
19
SECTION 12 SPARE PARTS LISTING
ALWAYS QUOTE APPLIANCE MODEL & SERIAL NUMBER AND GAS TYPE FOR SPARE PARTS
12.1 Gas components
DESCRIPTION
PART NE
MAKERS REFERENCE
APPLICATION
Air stream burner 6"
50 60200 005L01
"Midco" 60,8 kW
DFMA 5
Air stream burner 12"
50 60200 010L01
"Midco" 121,6 kW
DFMA 5 or 10
Air stream burner 18"
50 60200 015L01
"Midco" 182,4 kW
DFMA 5 or 10
Air stream burner 24"
50 60200 020L01
"Midco" 243,2 kW
DFMA 10 or 18
Air stream burner 30"
50 60200 025L01
"Midco" 304,0 kW
DFMA 10 or 18
Air stream burner 36"
50 60200 030L01
"Midco" 364,8 kW
DFMA 18
Air stream burner 42"
50 60200 035L01
"Midco" 425,6 kW
DFMA 18
Air stream burner 48"
50 60200 040L01
"Midco" 486,4 kW
DFMA 18
Main gas valve
30 60779 240
¾”BSP VE 4020A 1021
DFMA 5
Main gas valve
30 60775 240
1” BSP VE 4025A 1020
DFMA 10
Main gas valve
30 60776 240
1 1/2”BSP VE 4040A 1029
DFMA 18
Main gas valve
30 60778 240
2" BSP VE 4050A 1028
DFMA BC
Ignition burner gas valve
03 25169 240
1/4" BSP valve Scem
All
Main gas governor
03 25102
Max. RV 52 3/4" BSP
DFMA 5
Main gas governor
03 25103
Max. RV 53 1" BSP
DFMA 10
Main gas governor
03 25105
Max. RV 81 1 1/2" BSP
DFMA 18 non-modulating
Modulating gas regulator
30 60663
Max. M 611 3/4"
DFMA 5 modulating
Modulating gas regulator
30 60672
Max. M 611 1"
DFMA 10 modulating
Modulating gas regulator
30 60653
Max. MR 212 12"
DFMA 18 modulating
Modulating gas regulator
30 60671
max. MR 212 2"
DFMA BC
Modulating gas regulator
03 25159
1/4" BSP
all
12.2 Control components
DESCRIPTION
PART NE
MAKERS REFERENCE
APPLICATION
Automatic burner control TFI 812
03 25170 10 230
Satronic
all
Ignition transformer
30 61613, type ZE 23/8,5
Trafo Union
all
Maxitrol amplifier A 1044
30 60606 A 1044
Maxitrol
Maxitrol amplifier A 1014
30 60606 A 1014
Maxitrol
Temperature limiter
30 60504
Honeywell 14008E 1040
Differential pressure switch
30 60615
Huba
Temperature selector
30 60661 TD114
Maxitrol TD114 (option)
Temperature selector
30 60661 TD244
Maxitrol TD244
Duct sensor
30 60668 TS114
Maxitrol TS114
Duct sensor
30 60669 TS244
Maxitrol TS244
Mixing tube
30 60669 112
Maxitrol MT1-12
as per order
20
12.3 Option : Air filters
DIMENSION
PART NE
TYPE
QTY USED ON
405 X 510 X 25
(16" X 20" X 1")
60 61041 16x20
EU 4
DFMA 5 = 6
405 X 510 X 25
510 X 510 X 25
(16" X 20" X 1")
(20" X 20" X 1")
60 61041 16x20
60 61041 20x20
EU 4
DFMA 10 = 3
DFMA 10 = 6
510 X 635 X 25
405 X 635 X 25
(20" X 25" X 1")
(16" X 25" x 1")
60 61041 20x25
60 61041 16x25
EU 4
DFMA 18 = 9
DFMA 18 = 6
SECTION 13 HEALTH AND SAFETY STATEMENT
Health and Safety Information for the Installer, Commissioning/Service Engineer and User
Under the Consumer Protection Act 1987 and Section 6 of the Health and Safety at Work Act 1974 we hereby provide the
following information on substances hazardous to health. Product range reference: " DFMA AIR HEATERS"
Reznor DFMA Air Heaters when operating discharge the products of combustion into the space where persons may be present
who will inhale the diluted products, this is recognised practice for this type of appliance. You are hereby advised that no
unsafe condition will exist provided that the conditions for the installation outlined in this document have been observed.
13.1
During first firing some smoking may occur, this is
due to the burning off of protective/lubricating oils
used during appliance production. Most of this will
have been removed during the production testing
process. It is a wise precaution to ensure that
adequate ventilation is provided during the initial
firing and throughout the commissioning period,
this is particularly important if the discharge air is
to blow into a confined space. This smoking does
not constitute a poison hazard.
13.2
Reznor products contain no asbestos; copper is
not employed in gas carrying components; solder
which has a melting point below 450EC is not
used; paints for corrosion protection and decoration
are heat cured and contain no lead.
13.3
The above appliances meet the Electrical Safety
requirements of EN60 335 Pt 1 1988.
13.4
Small quantities of adhesives and sealants used in
the product are dried and cured and present no
known hazard.
13.5
Insulation and Seals.
Material: Synthetic Ceramic Fibre with Organic
binder.
Description: Tapes and Papers
Known hazards: Some people can suffer reddening
and itching of the skin. Fibre entry into the eyes
will cause foreign body irritation.
Inhalation will cause irritation to the respiratory
tract. As with any dust pre-existing respiratory
condition and lung diseases may be aggravated.
Precautions: Wear protective gloves when handling.
If abrading and dust is generated suitable protective
respirators must be used.
People with a history of skin complaints may be
susceptible to irritation.
Dust levels are only likely when the material is
abraded.
In general normal handling and use for this purpose
will not present discomfort. Follow good hygiene
practices, wash hands before consuming food or
using the toilet.
First Aid: Medical attention must be sought
following eye contact or prolonged reddening of the
skin.
13.6
Thermostat.
Material: Illuminating Kerosene.
Description: Sealed phial contains a small quantity
in liquid form.
Recognition:
Colourless
liquid,
paraffin
oil/petroleum hydrocarbon odour.
Characteristics: Non-corrosive, flammable with no
poisonous reference - CH poison Class 3
Precautions: Avoid handling. This product can
irritate and defat the skin. Prolonged contact may
cause dermatitis. Avoid breathing vapour. Avoid
eye contact.Do not ingest.
First Aid: Skin. Wash thoroughly with soap and
water.
Eyes. Rinse immediately with copious amounts of
clean water.
Ingestion: Seek medical advice.
NOTE: If skin irritation persists seek medical advice.
Prolonged exposure for the purposes envisaged
pertaining to this Reznor product is not anticipated.
21
13.7
Electrolytic Capacitor 1 Phase motors
Two types are used by random selection:
Recognition: 1.Plastic enclosure
2.Aluminium
enclosure
Material: Contained liquid electrolyte
Known hazards: Electric shock possible if charged.
Precautions: Discharge to ground/earth. Do not
incinerate.
First Aid: Treat for electric shock if affected.
SECTION 14. USER INSTRUCTIONS
DFMA AIR HEATERS
SPECIAL NOTE : The following instructions have been written assuming that the Reznor DFMA air heater is installed as a
heating/ventilating appliance.
OPERATING
How the air heater works:
Gas is burned by an airstream burner which fires into a
combustion chamber within the appliance air stream. The
gas burner is controlled by a double gas valve via an
electronic burner control, which is actuated automatically
via external controls i.e. a room thermostat and/or a time
switch. The burner is ignited by a spark igniter. The burner
will not fire until the air circulation fan is running and
proved at the appropriate rate. The air circulation fan also
provides the combustion air for the burner.
Safety:
1. Flame failure is detected by sensor and will immediately
cause safe shut down of the burner.
2. Safety against overheating is assured by thermally
activated overheat control/s. These control/s require resetting in the event that an overheat situation arises i.e.
as a result of blocked air filters, etc. Manual intervention
within the appliance is necessary to reset this control
device. Resetting of the automatic burner control may
also be required.
To light the heater:
1.
2.
3.
4.
5.
6.
7.
Turn on the gas supply to the air heater.
Switch on the electricity supply to the air heater.
Ensure time switch (if fitted) is set to a 'ON' cycle.
Switch appliance controls to ON.
Air heater will light automatically
If the appliance does not light:
a) check that the burner control does not require
resetting. An indicator light glows at the front panel
of the appliance and on a remote control if fitted).
Reset by pushing light/button on appliance or the
remote control.
b) check if thermal overheat control requires
resetting.
If the thermal overheat control requires resetting
and doing so restarts the burner, wait until the
appliance warms to thermal equilibrium, to ensure
the overheat control does not lock out again. If it
does and the temperature of the incoming air is less
than the set point of the thermal overheat control
then switch off the appliance and call for service.
Air circulation:
The space heating process is for air to be drawn through
the appliance whereby it gains heat from the burner. The
air is directly discharged into the space to be heated. In
some installations a proportion of the air may be
recirculated via the air heaters. Therefore it is very
important that an unobstructed path for the circulation of
the air will be maintained. This is particularly important if
the air heater is used for re-circulation and has been
installed to blow through the wall between two rooms.
Maintenance:
1. Maintenance and service must only be carried out by
appropriately qualified persons e.g. "Corgi" registered
undertakings.
2. It is in your interest to ensure service and maintenance
is carried out at regular intervals. Periods between
service are dependent upon the local environment where
the heater is installed. All gas appliances should be
serviced at least once a year.
3. In case of any damage to the appliance, it must be shut
down completely and checked by an appropriately
qualified person.
4. In the event of difficulties in resolving any of these
matters, please do not hesitate to contact Reznor or
their official distributor.
Important ;
Reznor DFMA air heaters are used where there is a need for
replacement air when powered air extraction is used. It is
necessary at all times that the extraction plant operates in
conjunction with the air heater.
Warning notices should be placed and advise must be given
to personnel employed in places where Direct Fired Air
Heating is installed to ensure that the conditions of
operation are understood and that air ways acting as
ventilation paths should not be blocked in any manner
albeit only temporarily.
Direct fired air heaters fitted with air filters must be
checked regularly to ensure that they are not blocked thus
causing nuisance shut-down of the gas burner. A routine
schedule should be drawn up to check and clean or replace
air filters.
22
Reznor DFMA SERIES
ONE OF THE NEW GENERATION OF CE MARKED GAS FIRED
ENERGY EFFICIENT AIR HEATERS
BEST USED WITH OUR OPTIONAL ELECTRONIC CONTROL PANELS
SAVE ENERGY AND OPTIMISE THERMAL COMFORT
23
ANNEX 1
Reznor Europe N.V.
Manufacturers Inspection/Test report;
Direct Gas Fired Air heaters
Date: / /
This appliance has been tested and set at the factory prior to shipping. Installed operating conditions may vary from those
specified due to change in air flow duty, etc. It is the responsibility of the commissioning engineer to ensure that the heat
input is adjusted to that to which the appliance was originally set. After making adjustments, record the details of the settings
on this document. Leave one copy with the appliance installation instructions and send a further copy to Reznor Europe N.V.
(* = option)
Order ref. :
File nE :
Model DFMA
..............................................
Nom. air flow
.......................................m3/h
Heat high input GCV
...................................kW
Type ventilateur
.....................................................
Motor rating
...................................kW
Motor serial nE
.........................................
Motor FLC
.....................................A
Motor speed (high)
...................................RPM
Drive pulley
..........................................mm
Type pulley
...........................................mm
Fan speed (high)
.................................RPM
Burner type
.....................................
Gas valve type ign. burner
...................................
Main gas valve type
....................................
Profile opening height
................................mm
Temperature rise
......................................EC
GCV test gas
.......................................kW/m3
Burner control type
.....................................
Burner modulation type
..................................
Work order NE :
Serial nE
................................................
*Low speed air flow
................................m3/h
*Heat input low rate
...................................kW
Motor type
...............................................
*Motor rating low speed
................................kW
*Motor FLC
.....................................A
*Motor low speed
.....................................RPM
Drive pulley
.....................................mm
Drive pulley setting
.......................................
*Fan speed low
................................RPM
Burner size
............................................ft
Safety gas valve
........................................
Profile length
.........................................mm
Profile area
...........................................m2
Gas type :
G20 G25 G30 G31
Gas rate
.............................................m3/h
Burner control serial nE
.................................
BURNER DATA
Minimum inlet gas pressure to obtain rate .............................................................................mbar
*Gas p switch set high
...........................mbar
*Gas p switch set low
...........................mbar
Burner gas pressure 1 stage
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Burner gas pressure modulating type
2 speed :
*Vmax/HS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
*Vmax/LS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Gas consumption : high rate ........m3/h
low rate .......m3/h
24
*Vmin/HS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
*Vlmin/LS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Gas consumption : high rate ........m3/h
*pd tested (Vmax)
*pst tested (Vmax)
*pst unit (Vmax)
<p profile (Vmax)
Air flow (Vmax)
Low rate ........m3/h
TEST DUCT
.....................................Pa
*pd tested (Vmin)
.....................................Pa
*pst tested (Vmin)
......................................Pa
*pst unit (Vmin)
.....................................Pa
<p profile (Vmin)
......................................m3/h
Air flow (Vmin)
.....................................Pa
.....................................Pa
.......................................Pa
.......................................Pa
.........................................m3/h
MOTOR PERFORMANCE ON TEST
*Input high speed (Vmax)
...............................A
*Input low speed (Vmin)
................................A
*Overload setting HS (Vmax)
....................A
*Overload setting LS (Vmin)
....................A
*Starting current HS A star (Vmax)
....................A
*Starting current LS A star(Vmin)
....................A
*Starting current HS A delta (Vmax)
....................A
*Starting current LS A delta (Vmin)
....................A
Starter delay
................................sec
Starting current 1 phase
................................A
APPLIANCE TEST PERFORMANCE
Air flow proving set high speed
....................mbar
opens " ........mbar
closed " ........mbar
*Air flow proving set low speed)
......................mbar
opens " ........mbar
closed " ........mbar
Gas governor outlet set high rate ........................mbar
Gas governor set low rate
............................mbar
*Inlet thermostat set
.................................EC
...................................EC
*Low temp. thermostat set
............................EC
High temp. thermostat set
.............................EC
Flame current high rate
.........................mA
*Flame current low rate
.........................mA
*Measured heat input high rate
.........................kW
*Measured heat input low rate
.........................kW
COMBUSTION
CO low rate
..........ppm
CO2 low rate
..........%
NOx
..........ppm
CO high rate
CO2 high rate
NOx
..........ppm
..........%
..........ppm
Wiring diagram ref.....................................................................
Testers name .............................................................
Testers signature
N.B. :* Indicates options and/or variables, single or two speed fans enter data as appropriate
Notes :
Legend
Vmax
Vmin
HR/HS
LR/LS
max. motor speed
min. motor speed
high rate / high speed
low rate / low speed
P
pd
pst
<P
pressure
dynam. pressure
stat. pressure
pressure difference
CO
CO2
NOx
carbon monoxide
carbon dioxide
nitric oxide
25
Reznor Europe N.V.
Installers Inspection/Test report;
Direct Gas Fired Air heaters
Date: / /
(* = option)
Order ref. :
File nE :
Model DFMA
..............................................
Nom. air flow
.......................................m3/h
Heat high input GCV
...................................kW
Type ventilateur
.....................................................
Motor rating
...................................kW
Motor serial nE
.........................................
Motor FLC
.....................................A
Motor speed (high)
...................................RPM
Drive pulley
..........................................mm
Type pulley
...........................................mm
Fan speed (high)
.................................RPM
Burner type
.....................................
Gas valve type ign. burner
...................................
Main gas valve type
....................................
Profile opening height
................................mm
Temperature rise
......................................EC
GCV test gas
.......................................kW/m3
Burner control type
.....................................
Burner modulation type
..................................
Work order NE :
Serial nE
................................................
*Low speed air flow
................................m3/h
*Heat input low rate
...................................kW
Motor type
...............................................
*Motor rating low speed
................................kW
*Motor FLC
.....................................A
*Motor low speed
.....................................RPM
Drive pulley
.....................................mm
Drive pulley setting
.......................................
*Fan speed low
................................RPM
Burner size
............................................ft
Safety gas valve
........................................
Profile length
.........................................mm
Profile area
...........................................m2
Gas type :
G20 G25 G30 G31
Gas rate
.............................................m3/h
Burner control serial nE
.................................
BURNER DATA
Minimum inlet gas pressure to obtain rate .........................................................................mbar
*Gas p switch set high
...........................mbar
*Gas p switch set low
...........................mbar
Burner gas pressure 1 stage
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Burner gas pressure modulating type
2 speed :
*Vmax/HS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
*Vmax/LS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Gas consumption : high rate ........m3/h
low rate ........m3/h
26
*Vmin/HS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
*Vlmin/LS
P1 cabinet ........mbar + P2 manifold ........mbar = Ptot ........mbar
Gas consumption : high rate ........m3/h
*pd (Vmax)
*pst (Vmax)
*pst unit (Vmax)
<p profile (Vmax)
Air flow (Vmax)
TEST DUCT
.....................................Pa
*pd (Vmin)
.....................................Pa
*pst (Vmin)
......................................Pa
*pst unit (Vmin)
.....................................Pa
<p profile (Vmin)
......................................m3/h
Air flow (Vmin)
Low rate ........m3/h
.....................................Pa
.....................................Pa
.......................................Pa
.......................................Pa
.........................................m3/h
MOTOR PERFORMANCE ON TEST
*Input high speed (Vmax)
...............................A
*Input low speed (Vmin)
................................A
*Overload setting HS (Vmax)
....................A
*Overload setting LS (Vmin)
....................A
*Starting current HS A star (Vmax)
....................A
*Starting current LS A star(Vmin)
....................A
*Starting current HS A delta (Vmax)
....................A
*Starting current LS A delta (Vmin)
....................A
Starter delay
................................sec
Starting current 1 phase
................................A
APPLIANCE TEST PERFORMANCE
opens " ........mbar
closed " ........mbar
Air flow proving set high speed
....................mbar
*Air flow proving set low speed)
......................mbar
opens " ........mbar
closed " ........mbar
Gas governor outlet set high rate ........................mbar
Gas governor set low rate
............................mbar
*Inlet thermostat set
.................................EC
...................................EC
*Low temp. thermostat set
............................EC
High temp. thermostat set
.............................EC
Flame current high rate
.........................mA
*Flame current low rate
.........................mA
*Measured heat input high rate
.........................kW
*Measured heat input low rate
.........................kW
Wiring diagram ref.....................................................................
Testers name .............................................................
Testers signature
N.B. :* Indicates options and/or variables, single or two speed fans enter data as appropriate
Notes :
Legend
Vmax
Vmin
HR/HS
LR/LS
max. motor speed
min. motor speed
high rate / high speed
low rate / low speed
P
pd
pst
<P
pressure
dynam. pressure
stat. pressure
pressure difference
27