Schwank | infraSchwank D 40U | Operating instructions | Schwank infraSchwank D 40U Operating instructions

Schwank infraSchwank D 40U Operating instructions
-
infraSchwank D / calorSchwank D
Radiant Tube Heater
15 U / 20 U / 30 U / 40 U
with single-, two-stage or modulating operation
AGA Certificate 7652
0085BO0037
Technical Instructions
Operating Instructions
Legal Requirements
Assembly Instructions
Installation Instructions
Commissioning
Service Guide
Version 005 infra_calor D shape U Australia 42/14
Technical specification subject to change
Technical Manual
Contents
1
2
Introduction ................................................................................................................ 3 Your Safety ................................................................................................................ 3 SCHWANK GmbH
Bremerhavener Str. 43 • 50735 Cologne • Germany
Postfach 62 02 49 • 50695 Cologne • Germany
Tel.: + (49) (0) 221- 7176 0
Fax: + (49) (0) 221- 7176 288
Internet: www.schwank.de
Schwank companies in: Austria ▪ Benelux ▪ Canada ▪ Czech Republic ▪ France ▪ Germany ▪ Great Britain ▪ Hungary
▪ Poland ▪ Romania ▪ Russia ▪ USA ▪ Distribution in more than 40 countries worldwide
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Notes for your safety .................................................................................................................... 3 3 Scope of Delivery ...................................................................................................... 4 4 Planning ..................................................................................................................... 6 Position of suspension .................................................................................................................. 6 Positioning .................................................................................................................................... 7 Air supply / Exhaust Requirements .............................................................................................. 8 5 Legal Requirements ................................................................................................ 15 6 Operating ................................................................................................................. 15 Switching on the heater .............................................................................................................. 15 Switching off the heater .............................................................................................................. 15 Fault ............................................................................................................................................ 15 Maintenance ............................................................................................................................... 15 7 Technical specification ............................................................................................ 16 Technical data ............................................................................................................................ 18 8 Operating description .............................................................................................. 19 9 Assembly instructions .............................................................................................. 20 10 Installation instructions ........................................................................................... 24 Gas-pipe-system and mounting of heaters ................................................................................. 24 Electrical installation (wiring diagram) ........................................................................................ 26 11 Commissioning instructions ................................................................................... 29 Adjusting nominal thermal load at single-stage operation .......................................................... 29 Adjusting thermal load at two-stage operation........................................................................... 30 Adjusting thermal load for modulating operation ........................................................................ 31 12 Service guide / Trouble shooting ............................................................................ 32 13 Change of gas family ............................................................................................... 33 14 Accessories ............................................................................................................. 34 Ball guards .................................................................................................................................. 34 Reflector elongation .................................................................................................................... 37 Set angled mounting tubes ......................................................................................................... 37 Water protection cover ............................................................................................................... 38 Gas filter - groups ....................................................................................................................... 39 15 Spare parts .............................................................................................................. 40 Spare parts infra D / calor D 15-40U .......................................................................................... 40 Spare parts burner unit infra D / calor D 15-40U ........................................................................ 41 16 AGA Certification ..................................................................................................... 42 17 EC type examination certificate ............................................................................... 43 18 EC declaration of conformity .................................................................................. 45 infraSchwank D / calorSchwank D - shape U
1 Introduction
Thank you for choosing a high efficiency SCHWANK
radiant tube.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Your infraSchwank D / calorSchwank D is a modern
and low-pollution tube heater for economic and
comfortable heating of industrial and commercial
buildings.
Notes for your safety
This appliance is designed according to the
requirements of the existing standards. Nevertheless
it is possible that dangers for you and others result
from the installation and/or operating errors.
To avoid this, please read and follow the instructions
carefully.
The design and operation of the heater are according
to the requirements of the existing standards.
General Notes
Please read this manual carefully before using the
heater. Please follow carefully all instructions and
warnings. The manufacturer will not be held
responsible for damages resulting from installation
errors or failure to comply with the manufacturer’s
instructions.
This manual is an integral and essential part of the
product and must be given to the user. Keep the
manual near the heater.
Grey marked text shows information to two-stage or
modulating operation for tube heaters
infraSchwank D / calorSchwank D
Follow carefully all warnings in chapter 2 “Your
Safety”.
These tube heaters are constructed exclusively for the
application of large industrial and commercial space
heating. Any other use is not permitted and therefore
Schwank is not liable for any improper use.
Only use the radiant tube if it is in a technically
faultless condition.
Any person pursuing any of the following tasks must
read this manual:
 operating
 assembling
 installation
 commissioning
 maintenance / trouble shooting
You need an explicit permission from the manufacturer
for any kind of changes and reconstruction.
Use original spare parts only.
2 Your Safety
You will find the following symbols in this manual:
Danger!
Note that you and others can be hurt.
Safety for the electrical equipment
Danger of electrical shocks!
Electrical shocks can be very dangerous!
The electrical installation must be carried out by a
qualified service engineer following the existing
national and international standards.
Check the electrical equipment regularly.
Defect wires etc. must be replaced immediately.
Attention!
Note that the appliance can be damaged.
Danger!
Note that electrical shocks can be very
dangerous. Pay attention while working on
the electrical equipment.
The appliance must be cut off from the power supply
while working with the electrical equipment. Make
sure that nobody can connect the appliance to the
power supply while you are installing or maintaining
the unit.
After-sales Service
For all installation operations, start-up, gas changes,
etc. always consult a qualified service engineer.
In case of doubt, please contact:

Advice!
You find additional instructions about the
application/handling of the heater.
Mr. John Balass
Devex Systems Pty Limited
5/83 Bassett St
Mona Vale NSW 2103
Tel: 02 9997 2811
Fax: 02 9997 7852
E-mail: info@devexsystems.com.au
3
infraSchwank D / calorSchwank D - shape U
3 Scope of Delivery
reflector long
turnaround box
turbulator
reflector short
suspension bracket
burner unit
tube
flange packing
Radiant tube infraSchwank D / calorSchwank D 20U
Scope of Delivery
The radiant tube infraSchwank D / calorSchwank D
consists of:
Accessories
 Burner-unit with gas-burner, pre-mixing chamber,
ignition and control unit, firing device, gas
combination valve (single-, two-stage or
modulating), air differential pressure switch,
electrical plug connection and fan
 Temperature regulating device
 Radiant tubes with turnaround box, flange packing
 Supply air- / exhaust flue-system
 Corrosion resistant reflector with end cap and
brackets for hanging
(calorSchwank D: isolated reflectors)
 Brackets for wall mounting of angled position (15-30°)
for infraSchwank D / calorSchwank D
 Control box with on/off switch and indicator lamp
 Gas cock (gas connection)
 Gas hose connection
 Gas filter
 Flue gas adapter
 Ball protection grids (for sport halls)
 Reflector elongations
 Set for angled mounting
 Water protection cover (stainless steel)
4
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Fig 1:
tube bar
infraSchwank D / calorSchwank D - shape U
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Structure of the burner unit
Fig. 2:
Burner unit
1. Controller
2. Air differential pressure switch
3. Fan air restrictor plate
4. Fan
5. Air baffle plate (only 15 / 20 / 30 / 40U)
6. Gas combination valve
(single-, two-stage or modulating)
14. Ignition and ionisation electrode
15. Ignition cable
16. Ionisation cable
17. 3-pin power supply socket
18. Locking screw
19. Venturi
7. Test nipple connection pressure
20. Burner baffle (only 15 / 20 / 30 / 40U)
8. Test nipple nozzle pressure
21. Gasket
9. Adjustment screw nozzle pressure
10. Adjustment screw start step valve
11. Inspection glass
12. Burner cup
13. Burner nozzle
5
infraSchwank D / calorSchwank D - shape U
4 Planning
Do not place articles on or against
this appliance.
Room temperature control
Do not use or store flammable
materials near this appliance.
Radiant tube heating-systems must be equipped with
a temperature control.
Do not spray aerosols in the
vicinity of this appliance while it is
in operation.
Section heating is allowed without temperature control.
Position of suspension
Suspension height
Radiant tubes must be positioned so that no one in
the radiation area is exposed to an extreme high heat
level. This is ensured when the minimum suspension
heights shown in the following table are adhered to:
Suspension height in m
2
(max. radiation 200 W/m )
A = horizontal
B = angled (30°)
3.5m
4.0m
4.8m
5.5m
3.1m
3.6m
4.3m
4.9m
60 (15U)
75.9 (20U)
115.9 (30U)
155.8 (40U)
Tab 1:
Key:
Minimum suspension heights
A = Minimum height when hanging horizontally
B = Minimum height when hanging angled
b
[cm]
Fig 3: Suspension heights and distances for horizontal
application
d
[cm]
Type
a
[cm]
infra
calor
infra
calor
15 U
110
20
10
50
15
15
20 U
110
20
10
50
15
15
30 U
130
20
10
50
15
15
40 U
170
25
10
50
25
15
Tab 2:
c
[cm]
Safe distances
Key:
a = Minimum radial safety distance (inside radiation area)
b = Minimum upper safety distance when hanging horizontally
c = Minimum upper safety distance when hanging angled
d = Minimum lateral distance to supply pipes outside radiation area
Distances to flammable materials in the
radiant area
Radiant tubes must be positioned so that the surface
temperature of
 components with flammable materials,
 flammable equipment, stored flammable materials
not exceed 65°C above ambient.
6
Fig 4:
Suspension heights and distances for angled
application
Direction of radiation
Radiant tubes infraSchwank D / calorSchwank D can
be positioned horizontal or at an angle (max. 30° from
vertical). For this purpose suspension steel chains
and cables are installed at the suspension brackets.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Nominal
thermal load in
MJ/h (type)
infraSchwank D / calorSchwank D - shape U
Positioning
The radiant tube can be mounted with
 chains (links min. 4 mm)
 adjustable steel cable (Schwank accessories)
If you chose chains please use bolts with lock nuts for
fixing the chain to the suspension bracket.
wrong
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
The radiant tube has to be fixed by
vertical chains etc. to the roof or to
supporting devices.
Chains and steel cables have to be
fixed in vertical direction or slightly
diagonally outwards above the fixing
points of the suspension brackets to
the roof or to supporting devices.
Fixing of the suspension cables or
chains diagonally inwards to the centre
of the heater is not permitted
(see Fig 5).
wrong
Please note that the radiant tube being
in operation expands several
centimetres because of thermal
expansion. Avoid therefore inflexible
suspension.
Do not use fixing elements like open
hooks etc.
Hang the heater in balance. We recommend the use
of turnbuckles or adjustable steel cable grips for ease
of adjustment and balance.
Fixing points for chains or steel cables on the heater
are shown in Fig. 13 and 14 on pages 16 and 17.
correct
Fig 6: Slope of radiant tube heater
SCHWANK GmbH will not accept liability
for damages caused by incorrect mounting
of the burner unit. Correct mounting is the
responsibility of the installer.
Attention!
If you do not align the burner unit
correctly the device can be damaged.
x
x
Correct = vertical or slightly
diagonally outwards
15/20/30U: x=15mm
40U: x=20mm
Wrong = diagonally inwards
Fig 5: Chains and steel cable mounting
7
infraSchwank D / calorSchwank D - shape U
Air supply / Exhaust Requirements
Air supply / exhaust systems
The calculation of air supply / exhaust requirements of
a building heated by radiant tube heaters is subject of
Australia Standard AS 5601. Please follow local bylaws as well.
For the radiant tube infraSchwank D / calor SchwankD
the following air supply / exhaust systems are
possible:
Please see the max. lengths of combustion air supplyand exhaust flue pipe on page 9 (Tab 3, page 9).
1. Indirect flue into the room
(Type A3 without exhaust system,
combustion air from inside the room)
Place of Installation
2. Flued with individual exhaust system,
combustion air from inside the room
(Type B23)
The room to be heated must have an air volume of
minimum 10 m³ for each kW of the nominal thermal
load of the installed heater.
3. Flued with individual exhaust system,
combustion air from outside the room
(Type C)
Air supply (combustion air from inside
the room, types A3 and B23)
4. Flued with flue collecting system and
central flue fan – combustion air either from
inside or from outside
(according to EN 777, Type D)
In halls and buildings with a normal air change by
means of joints and gaps it is not necessary to install
additional equipment to ensure combustion air supply.
1. Indirect flue into the room
(Type A3 without exhaust system combustion
air from inside the room)
The exhaust air of the tube heater has to be
conducted from the inside of the room to the outside.
Conduction of the exhaust air may be carried out with
one of the following 3 methods:
a) Thermal ventilation: Combustion air and
exhaust air are to be conducted through
fixed outlets positioned on the roof or on the
walls of the building.
b) Mechanical ventilation: Combustion air
and exhaust air are to be conducted
through
one or more fans positioned on the roof or
on the walls of the building.
c) Natural ventilation: Combustion air and
exhaust air are to be conducted through
outlets as a result of differences in pressure
and in temperature between the internal
and external side of a building.

For exact dimensioning and positioning
of supply air and exhaust air outlet of
the building according AS 5601 or
please contact Schwank GmbH
8
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Heating installations with combustion air from inside
the room are only allowed in rooms without string air
pollution. Otherwise use system with combustion air
from outside (type C).
infraSchwank D / calorSchwank D - shape U
2. Exhaust flue with individual exhaust system combustion air from inside the room
(Type B23)
4. Exhaust flue with flue collecting system and
central flue fan
(according to EN 777, Type D)
Only use this system in rooms with no air pollution
and without relevant pressure differences to outside.
Otherwise use type C.
The heating installation must not exceed 10 radiant
tubes. The exhaust air of each tube is collected via a
central collecting tube system by a central flue fan and
led to the chimney. Planning, construction and layout
of such installations must be carried out by Schwank
employees, as well as commissioning. The strict
observance of the Schwank layout-drawings and
calculation figures are the precondition of the
manufacturer’s warranty.
3. Exhaust flue with individual exhaust system combustion air from outside the room
(Type C)
Combustion air and exhaust air are to be conducted
by a temperature stable, concentric pipe from a wall or
roof entrance.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Max. length of the concentric pipe can be 6 m plus
two 90° elbows.
The concentric pipe ends at a bifurcated pipe. Please
ensure that the connection for exhaust air between
heater and bifurcated pipe is a flexible pipe. Do not
use back-pressure valves or dampers in the exhaust
flue.
If the radiant tubes will be installed without their
individual flue fans, please note that it could be
necessary to install in the collecting tube behind each
radiant heater a damper or a pressure-balancing
device. This ensures a precise regulation and an even
exhaust flue of each radiant tube.

See technical instruction
infraSchwank D / calorSchwank D with
flue collecting system
infraSchwank D/ calorSchwank D, shape U
Max. length
max. number
between heater
Ø of
of elbows
and roof/wall
air/exhaust flue
(90°)
entrance
6m
2
100 mm
Tab 3: air / exhaust flue
Flexible exhaust system with
wall terminal
Flexible exhaust system with
wall terminal
Flexible exhaust system with
roof terminal
Flexible exhaust system with
roof terminal
Fig. 7: Air/exhaust--system,
version aluminium or stainless steel
9
infraSchwank D / calorSchwank D - shape U
Indirect flue into the room with flue gas diverter
Installation with indirect flue into
the room must be mounted with
flue gas diverter to avoid flow
back of flue gas in combustion air
stream.
Note that the flue gas diverter
(code no. 126 7018 0) is mounted
in a position so that the flue gas
is diverted from the burner.
flue gas diverter with right
mounting position
Fig 8: Flue less appliance with flue gas diverter
10
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
To prevent CO2 impingement on
wall when configured as an
indoor flue less appliance a
clearance of 1200mm from the
flue outlet is required.
infraSchwank D / calorSchwank D - shape U
Flexible exhaust system infraSchwank D / calorSchwank D 15-40U (wall terminal)
- version aluminium Please note the safety distance to
flammable materials:
- single-wall exhaust pipe: 40mm
- double-wall exhaust pipe + wall
terminal: 0mm
The stainless flexible pipe (exhaust
line) must be installed uncut for the
heater 40U. Make sure that there is no
sink in the pipe.
All socket connections on the
exhaust and air line must be locked
by means of self-tapping screws.
The wall terminal is mounted with a
small gradient to outside to prevent
intrusion of driving rain.
System certification tube heater
infraSchwank D / calorSchwank D
with exhaust line system
CE 0432-CPD-217915, System 0.2 / 0.5
(Muelink&Grol)

Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
The 90° elbow at the sucking fan side is
to mount with the opening on the top.
control points
exhaust gas:
stainless flexible pipe
wall terminal
combustion air:
15 - 20U: aluminium flexible pipe
30 - 40U: stainless flexible pipe
condensate collector
Fig 9: Position of control points 15 – 40U (wall terminal), version aluminium
11
infraSchwank D / calorSchwank D - shape U
Flexible exhaust system infraSchwank D / calorSchwank D 15-40 U (roof terminal)
- version aluminium The stainless flexible pipe (exhaust
line) must be installed uncut for the
heater 40U. Make sure that there is no
sink in the pipe.
All socket connections on the
exhaust and air line must be locked
by means of self-tapping screws.
Please note the safety distance to
flammable materials:
- single-wall exhaust pipe: 40mm
- double-wall exhaust pipe + wall
terminal: 0mm
The 90° elbow at the sucking fan side is
to mount with the opening on the top.

dimensions flat roof sockets
roof terminal
flat version
high version
control points
exhaust gas:
stainless flexible pipe
combustion air:
15 - 20U: aluminium flexible pipe
30 - 40U: aluminium flexible
condensate collector
Fig 10: Position of control points 15 – 40U (roof terminal), version aluminium
12
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
System certification tube heater
infraSchwank D / calorSchwank D
with exhaust line system
CE 0432-CPD-217915, System 0.2 / 0.5
(Muelink&Grol)
infraSchwank D / calorSchwank D - shape U
Flexible exhaust system infraSchwank D / calorSchwank D 15-40U (wall terminal)
- version stainless steel Install stainless steel flexible pipe
without sink.
Please note the safety distance to
flammable materials:
- single-wall exhaust pipe: 80mm
- double-wall exhaust pipe +
wall terminal: 0mm
Join parts of the roof terminal by
compression strongly together!
All joints inside the building tighten
securely with clamp fittings!
The 90° elbow at the sucking fan side is to
mount with the opening on the top.

Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
The wall terminal is mounted with a
small gradient to outside to prevent
intrusion of driving rain.
System certification tube heater
infraSchwank D / calorSchwank D with
exhaust line system
Future ew
CE 0432–CPD219983 /
Future ew-flex CE 0432–CPD-219952 /
Future dw
CE 0432-CPD-219996
(Schräder)
Fig. 11: Position of control points 15 – 40U (wall terminal), version stainless steel
13
infraSchwank D / calorSchwank D - shape U
Flexible exhaust system infraSchwank D / calorSchwank D 15-40U (roof terminal)
- version stainless steel Install stainless steel flexible pipe
without sink.
Please note the safety distance to
flammable materials:
- single-wall exhaust pipe: 80mm
- double-wall exhaust pipe +
roof terminal: 0mm
Join parts of the roof terminal by
compression strongly together!
All joints inside the building tighten
securely with clamp fittings!
The 90° elbow at the sucking fan side
is to mount with the opening on the
top.

System certification tube heater
infraSchwank D / calorSchwank D with
exhaust line system
Future ew
CE 0432–CPD-219983 /
Future ew-flex CE 0432–CPD-219952 /
Future dw
CE 0432-CPD-219996
(Schräder)
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
Fig. 12: Position of control points 15 – 40U (roof terminal), version stainless steel
14
infraSchwank D / calorSchwank D - shape U
5
Legal Requirements
6
Operating
We recommend that these installation guidelines
should be observed with the relevant Building
Standards Regulations of your country. Comply with
any local by-laws and the current IEE Wiring
Regulations.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Notwithstanding their limited scope, the appliance
should be installed by a competent person in
accordance with the relevant provisions of the Gas
Safety (Installation and Use) Regulations. Caution
must also be taken of any obligations arising from the
Health and Safety of Work Act. Full compliance with
all relevant regulations, including amendments in
force at the time of installation is a requirement of our
warranty.
The installation must be carried out by
a qualified engineer following the
manufacturer’s instructions.
SCHWANK will not accept liability damages
caused by improper assembly and/ or operating
of the heater. Proper assembly and operation is
the responsibility of the user.
Switching on the heater
 Switch on the heater. The main switch is on
the control box. After a pre-purge period of
about 25 sec. the ignition starts.
Switching off the heater
 Switch off the heater.
If the radiant tube is controlled by a thermostat the
heater will be switched on and off automatically.
Fault
If no flame is reported during the pre-purge period
and the safety time (approx. 30 sec.) the heater
repeats the ignition process. If there is no flame after
the second ignition process the radiant tube switches
off automatically and is locked.
Investigation and repair must be carried out by
authorized personnel. After clearance of the fault the
heater can be reset.
Lock release (Reset)
 Interrupt the electric power supply for
3 seconds.
Maintenance
Maintenance and servicing of the
appliance must be carried out by
authorised personnel and not less
than once a year.
Servicing of the heater is essential for continued
efficient operation.
After any servicing, the heater must be
recommissioned as detailed in Chapter 12.
15
infraSchwank D / calorSchwank D - shape U
7 Technical
specification
Appliance
Automatic heating device, heat transfer
by mean of infrared dark radiation.
Fuel Types
Natural gas
Propane
Electrical connection
Single phase A.C. 230 V, N, PE - 50Hz (cycles)
(approx. 80 VA)
Power supply for the heater and fan are connected to
the socket of the burner box. To set the burner box
free of voltage, it is only necessary to remove the
plug of the power supply.
Max. connection pressure
Natural Gas: 5.0kPa
Exhaust gas
Connection
Flue gas pipe connection Ø 100
at exit of tube
Gas connection
15-30U
40U
Type
Natural Gas
LPG
15-40U
1.13kPa
2.75kPa
R=1/2’’ male
R=3/4’’ male
Detail A
infraSchwank D / calorSchwank D 15U
Cross dimensions at burner unit
15-40U
A=80mm
(all dimensions in mm)
Detail A / B
infraSchwank D / calorSchwank D 20U
(all dimensions in mm)
Fig 13:
16
Measurements infraSchwank D / calorSchwank D 15U
and 20U (view from below)
Detail B
Cross dimensions reflector
valid for all types
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
Attention!
The connection cable for the lifting magnet of
2-stage gas combination valve must connect from the
connection box (230 V/50 Hz) to the provided luster
terminal inside of the burner unit.
The connection cable for the lifting magnet of
modulating gas combination valve must connect
direct from the modulation box to the lifting magnet.
The distance between modulation box and burner
unit should be < 1,5m.
Minimum connection pressure in front of valve
infraSchwank D / calorSchwank D - shape U
infraSchwank D / calorSchwank D 30U (all dimensions in mm)
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
infraSchwank D / calorSchwank D 40U (all dimensions in mm)
Fig 14: Measurements infraSchwank D / calorSchwank D 30U and 40U (view from below)
17
infraSchwank D / calorSchwank D - shape U
Technical data
for single, two-stage and modulating regulation
Gas
infraSchwank D / calorSchwank D
15U
20U
30U
Natural gas
Gas consumption [MJ/h]
1)
single state
Propane
2)
40U
59.9
75.9
115.9
155.8
Gas consumption [MJ/h]
2-stage/modulating max./min.
59.9 - 44.7
75.9 - 57.2
115.9 - 87.9
155.8 - 119.9
Gas consumption [MJ/h]
2-stage/modulating max./min.
58.7
74,4
113.5
152.6
Gas consumption [MJ/h]
2-stage/modulating max./min.
58.7 - 43.8
74.4 - 56.0
113.5 - 86.1
152.6 - 117.4
54 / 68
75 / 95
92 / 119
130 / 171
Weight infra / calor [kg]
 of air/exhaust flue [mm]
Electrical consumption [W]
Ø 100
104
IP 20
Electrical protection
3
R /4 “
R½“
Gas connection (male)
230 V/ 50 Hz ~
Ignition / Control
Spark ignition and ionisation control
by automatic controller system
CE - 0085 BO 0037
7652
CE-Identification
AGA Certification no.
3
1) Hi,B = 37.8 MJ/m / 2) Hi,B = 95.8 MJ/m
3
Tab 4: Technical data infraSchwank D / calorSchwank D
infraSchwank D / calorSchwank D
15U
20U
30U
40U
Gas
Burner nozzle [mm]
cipher burner nozzle
Fan air restrictor plate
Air baffle plate
Burner baffle plate
Nozzle pressure [kPa] 1-stage
2-stage / modulating
Start step pressure [kPa]
Start step adjustment [°]
Burner nozzle [mm]
cipher burner nozzle
Fan air restrictor plate
Air baffle plate
Burner baffle plate
Nozzle pressure [kPa] 1-stage
2-stage / modulating
Start step pressure [kPa]
Start step adjustment [°]
Natural gas
1)
Propane
2)
3
3
1) Hi,B = 37.8 MJ/ m / 2) Hi,B = 95.8 MJ/m
3.75
375
D 15
D 15
Ø 50
0.87
0.87 / 0.6
0.4
MIN
2.30
230
D 15
D 15
Ø 50
2.4
2.4 / 1.4
1.2
MAX
*) IA= inlet angle plate
Tab 5: Function parts burner unit infraSchwank D / calorSchwank D
18
4.10
410
D 20
D 20
Ø 50
0.87
0.87 / 0.6
0.4
MIN
2.50
250
D 20
D 20
Ø 50
2.4
2.4 / 1.4
1.2
MAX
5.35
535
D 30
D 30 + spin
Ø 65
0.87
0.87 / 0.6
0.4
MIN
3.15
315
D 30
D 30 + spin
Ø 65
2.4
2.4 / 1.4
1.2
MAX
6.25
625
D 40
D 40 U
/
0.83
0.83 / 0.6
0.3
MIN
3.60
360
D 40
D 40 U
Ø 65
2.4
2.4 / 1.4
1.2
MAX
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Electrical supply
infraSchwank D / calorSchwank D - shape U
8 Operating description
Start-up
If heat demand exists, the fan will start up automatically.
A differential pressure arises in the burner box, which is
reported to the ignition unit via the differential pressure
switch.
Fault
After a pre-purge period of about 25 seconds the
automatic ignition starts (max. ignition time 5 sec.). The
twin solenoid valve with pressure regulator opens the
gas supply to the burner in 2 steps. The burner flame is
controlled by an ionisation electrode. The ignition is
switched off, if the ionisation electrode reports a flame
to the ignition and control unit within the safety time.
Investigation and repair must be carried out by
authorized personnel only. After clearance of the
fault, the interlock can be reset.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
If the ignition process fails, the ignition unit repeats the
start-up for one more time.
Operation
A very long laminar flame is created in the first tube by
the special burner construction. The hot flue heats the
tube surface while being fed through the tubes by the
fan. The hot tubes emit long-waved infrared radiation
which is directed to the room by the reflector
construction.
The radiant tube infraSchwank D / calorSchwank D
work with a closed combustion system. The combustion
air is taken from the room or from the outside. The flue
is evacuated indirectly into the room or directly by the
exhaust pipe or by a special air/exhaust pipe system.
For optimal adaption of heaters´ performance to the
heat demand of the building heaters are offered in
2-stage or modulating operation.
Start and ignition of the heater has always to be in full
load. After a time of minimal 1 minute the heater can be
switched to small step.
If no flame is reported during the pre-purge period
(including 1 repetition of ignition process), the ignition
unit will switch off the radiant tube and will lock it.
The lock release can carried out by an interruption of
the electric power supply for 3 sec. A new start-up
begins. If no flame signal is reported to the ignition and
control unit during operation, the solenoid valve shuts
and stops the gas supply immediately. A new start-up
process is repeated.

Troubleshooting: page 32
Monitoring of the combustion air supply
The combustion air supply is permanently controlled by
the differential pressure switch during the operation.
If the differential pressure switch is not in rest position
during the start-up the operation will not start. If the
operating contact is not closed during the pre-purge the
system will set in interference release.
If combustion air supply fails during operation (lack of
air), the differential pressure switch will close the gas
combination valve and stop the gas supply. A new startup process is to be repeated.
.
19
infraSchwank D / calorSchwank D - shape U
9 Assembly instructions
infraSchwank D / calorSchwank D 15U

Tools you need
• hexagonal wrench or ratchet
(width: 10, 13)
• socket wrench (width: 7 and 8)
Note before mounting
 Note the distance measure of suspension brackets.
 Flanges are mounted with flange packing
(each 4 screws/washers/lock washers/nuts M8).
 Turn welding line of the tubes to the side.
 Tube with turbulator (with paint mark) has to be
mounted behind the turnaround box (flow direction).
The paint mark showing to the turnaround box!
 Tube bars have to be fixed by nuts/lock washers/3Dwashers M8 on the suspension bracket.
 First the reflector will be fixed on the U-bend
connection by self-tapping screws. For insulated
reflectors (calorSchwank D) the reflector end with
notch on sides shows to the turnaround box.
Accessory:
Flue gas adapter code no. 126 7035 0
Adapter is mounted at the end of the tube with
gasket.
 Flue gas connection (Type B23, C):
version stainless steel:
Note that the flue gas flexible pipe is mounted at the
end of the tube with gasket.
 The other reflector ending will be shoved under the
clip of the suspension brackets. Reflector and front
plate have to be fixed by self-tapping screws.
 Mounting of burner unit with valve on the top.
Flue gas diverter
Fig. 15: Mounting of infraSchwank D / calorSchwank D 15U
(all dimensions in mm)
20
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
 Start mounting the heater at the turnaround box
connection.
 Indirect flue into the room (Type A3):
Flue gas diverter code no. 126 70180
Note that the flue gas diverter is mounted in a
position so that the flue gas is diverted from the
burner.
infraSchwank D / calorSchwank D - shape U
Assembly
infraSchwank D / calorSchwank D 20U

Tools you need
• hexagonal wrench or ratchet
(width: 10, 13)
• socket wrench (width: 7 and 8)
Note before mounting
 Note the distance measures of suspension brackets.
 Flanges are mounted with flange packing
(each 4 screws/washers/lock washers/nuts M8).
 Start mounting the heater at the turnaround box
connection.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
 Turn welding line of the tubes to the side.
 Tube with turbulator (with paint mark) has to be
mounted behind the turnaround box (flow direction).
The paint mark showing to the turnaround box!
 Tube bars have to be fixed by nuts/3D-washers/lock
washers M8 on the suspension brackets.
 Start the reflector mounting at the turnaround box
connection with the longest reflector L=3000mm.
Reflector will be fixed on the turnaround box
connection by self-tapping screws. For insulated
reflectors (calorSchwank D) the reflector end with
notch on sides shows to the turnaround box.
 Indirect flue into the room (Type A3):
Flue gas diverter code no. 126 70180
Note that the flue gas diverter is mounted in a
position so that the flue gas is diverted from the
burner.
Accessory:
Flue gas adapter code no. 126 7035 0
Adapter is mounted at the end of the tube with
gasket.
 Flue gas connection (Type B23, C):
version stainless steel:
Note that the flue gas flexible pipe is mounted at the
end of the tube with gasket.
 The other reflector endings will be shoved under the
clips of the suspension brackets.
 The short reflector L=1500mm is mounted at the
front of the heater.
 Reflectors will be jointly fixed by 3x M 5 screws and
self-locking nuts.
 Reflector and front plate have to be fixed by selftapping screws.
 Mounting of burner unit with valve on the top.
Fig. 16:
Mounting of infraSchwank D / calorSchwank D 20U
(all dimensions in mm)
Flue gas diverter
21
infraSchwank D / calorSchwank D - shape U
Assembly
infraSchwank D / calorSchwank D 30U

Tools you need
• hexagonal wrench or ratchet
(width: 10, 13)
• socket wrench (width: 7 and 8)
 hand rivet tool, drill machine,
drill  4.9mm
Note before mounting
Fig. 17: Mounting of infraSchwank D / calorSchwank D 30U
(all dimensions in mm)
Flue gas diverter
22
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
 Note the distance measures of suspension brackets.
 Indirect flue into the room (Type A3):
 Flanges are mounted with flange packing
Flue gas diverter code no. 126 70180
(each 4 screws/washers/lock washers/nuts M8).
Note that the flue gas diverter is mounted in a
 Start mounting the heater at the turnaround box
position so that the flue gas is diverted from the
connection.
burner.
 Turn welding line of the tubes to the side.
Accessory:
 Tube with turbulator (with paint mark) has to be
Flue gas adapter code no. 126 7035 0
mounted behind the turnaround box (flow direction).
Adapter is mounted at the end of the tube with
The paint mark showing to the turnaround box!
gasket.
 Supporting sleeve for first flange connection:
Insert half of the supporting sleeve into first heater
 Flue gas connection (Type B23, C):
tube (slot on top). Drill Ø 4.9mm hole through the
version stainless steel:
tube and sleeve and fix it by rivet. Mount the second
Note that the flue gas flexible pipe is mounted at the
tube and fix the sleeve by the rivet as well. Fix the
end of the tube with gasket.
rivets always in the opposite position lateral to the
tube. Use only stainless rivets.
 Tube bars have to be fixed by nuts / 3D washers / lock
washers M8 on the suspension brackets.
 Start the reflector mounting at the turnaround box
connection. Reflector will be fixed on the turnaround
box connection by self-tapping screws. For insulated
Supporting sleeve
reflectors (calorSchwank D) the reflector end with
4 rivets (stainless steel)  4,8mm
notch on sides shows to the turnaround box.
hole
to drill  4,9mm
 The other reflector endings will be shoved under the
clips of the suspension brackets.
 Reflectors will be jointly fixed by 3x M 5 screws and
self-locking nuts.
 Reflector and front plate have to be fixed by selftapping screws.
 Mounting of burner unit with valve on the top.
infraSchwank D / calorSchwank D - shape U
Assembly
infraSchwank D / calorSchwank D 40U

Tools you need
• hexagonal wrench or ratchet
(width: 10, 13)
• socket wrench (width: 7 and 8)
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Note before mounting
 Note the distance measures of suspension brackets.
 Flanges are mounted with flange packing
(each 4 screws/washers/lock washers/nuts M8).
 Start mounting the heater at the turnaround box
connection.
 Turn welding line of the tubes to the side.
 Tube with turbulator (with paint mark) has to be
mounted behind the turnaround box (flow direction).
The paint mark showing to the turnaround box!
 Tube bars have to be fixed by nuts/3D-washers/lock
washers M8 on the suspension brackets.
 Start the reflector mounting at the turnaround box
connection. Reflector will be fixed on the turnaround
box connection by self-tapping screws. For insulated
reflectors (calorSchwank D) the reflector end with
notch on sides shows to the turnaround box.
 The other reflector endings will be shoved under the
clips of the suspension brackets.
 Reflectors will be jointly fixed by 3x M 5 screws and
self-locking nuts.
 Reflector and front plate have to be fixed by
self-tapping screws.
 Mounting of burner unit with valve on the top.
Fig. 18:
Mounting of infraSchwank D / calorSchwank D 40U
(all dimensions in mm)
 Indirect flue into the room (Type A3):
Flue gas diverter code no. 126 70180
Note that the flue gas diverter is mounted in a
position so that the flue gas is diverted from the
burner.
Accessory:
Flue gas adapter code no. 126 7035 0
Adapter is mounted at the end of the tube with
gasket.
 Flue gas connection (Type B23, C):
version stainless steel:
Note that the flue gas flexible pipe is mounted at the
end of the tube with gasket.
Flue gas diverter
23
infraSchwank D / calorSchwank D - shape U
10 Installation
instructions
Danger of fire and explosion!
Unprofessional handling of gas pipes,
gas connections and the appliance can
produce gas leaks. It is highly dangerous
if gas is ignited!
Working on gas pipes and the appliances
is only allowed by approved installers.
Mount the flexible connection, so that it
can compensate the longitudinal
expansion of the tube.
infraSchwank D / calorSchwank D shape U
min.
connection
pressure
type
[kPa]
Natural
gas*
15 - 30U
40U
Propane* 15 - 40U
1.13
2.75
nozzle pressure
start step
pressure
single
stage
[kPa]
two stage /
modulating
max. - min.
[kPa]
[kPa]
0.87
0.87 - 0.6
0.4
0.83
0.83 - 0.6
0.3
2.4
2.4 - 1.4
1.2
* Natural gas: HS,B: 37,8 MJ/m3 Propane: HS,B 95.8 MJ/m3
Tab 6: min. connection pressures with single and two stage
regulation in front of gas combination valve
Pressure drop Schwank gas-pipe-systems
infraSchwank D / calorSchwank D shape U
Natural
gas
a
Propane
type
gas pipe system
15 - 30U
1/2" / L=800mm
pressure drop
[kPa]
0.2
40U
3/4" / L=800mm
0.25
15 - 30U
1/2" / L=800mm
0.1
40U
3/4" / L=800mm
0.1
Tab 7: Pressure drop Schwank gas-pipe-systems
b
Fig 19: Longitudinal expansion
Gas-pipe-system and mounting of
heaters
In case of contaminated gas pipes and
generally at gas pipes of welded black
steel have to be mounted
gas filter - groups directly in front of the
heater (see page 39).
All gas installation work must be carried
out only by an authorised person in
accordance with standard AS 5601.
Additional installation notices of national or local
institutions must be observed. The pipe must be
dimensioned in a way that the minimum connection
pressure in front of the gas combination valve of the
individual devices is available at the nominal thermal
load of the entire system, according to table 6.
Flexible final connections to the heater must either
a) hose assembly to AS/NZS 1869 of a suitable size,
temperature and pressure rating or
b) a limited flexibility connector to AS 4631 of a
suitable size.
Please consider the pressure drop of the upstream
mounted gas connection and gas filter. For the detailed
pressure drop value of the Schwank gas-pipe-systems
see table 7.
24
Technical specification subject to change
The max. connection pressure for
natural gas is 5.0kPa!
Version 005 infra calor D shape U Australia 42/14
Only use flexible connections for the
radiant tube regarding:
• gas
• electricity and
• air (if necessary)
Minimum connection pressures in front of valve
infraSchwank D / calorSchwank D - shape U
Note the following points while installing the
gas-pipe-system:
 Use only gas lines as per national standards,
refer to AS 5601 for pipe size details.
430 mm
(+/- 10%)
 Never hang heaters on the gas pipes.
 Mount a manual gas cock upstream of every
radiant tube.
 Close all gas cocks before carrying out the leak
test and disconnect the connection between the
gas cock and the burner to avoid damages to the
gas regulator and gas combination valve.
Fig 16: lateral connection 90° bend
 Clean gas pipes before the installation of the
heater. Reconnection after pressure control and
expansion.
430 mm
(+/- 10%)
Please observe the national standards.
Connect the heater with an approved
flexible hose.
a = 320 mm +/- 10%
h = 150 mm
h: allowable height
displacement for mounting
 Use the following hose length:
15-30U
R ½“
length 800mm
40U
R ¾“
length 800mm
 Mount only a flexible hose with 90° bend or with
2 x 90° elbow with 180° bend according to
fig. 20, 21 and 22.
 Keep the specified installation dimensions.
 Wrong mounting of flexible hoses shown in
Fig. 23 (sketches  to)
Fig. 22: Alternative flexible hose 180° -bend with 2 x 90° elbow

430 mm
(+/- 10%)
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Fig. 21: lateral connection 90° bend


430 mm
(+/- 10%)
Fig 23: Wrong mounting of flexible hoses
Fig 20: Stand connection 90° bend
25
infraSchwank D / calorSchwank D - shape U
Gas connection has to be positioned in
the axle of the heater. Otherwise
torsional forces will operate on the hose!
Avoid twisting of the flexible hose!
(When tightening the union, counter hold
the nipple on the hose.)
Pay attention that the flexible hose will
not be mechanically damaged by tools
etc. Do not buckle the hose.
Do not mount damaged flexible hoses!
Damaged hoses can break due to the
movement of the heater.
Electrical installation
(wiring diagram)
Isolate the electrical supply while
working at the electrical equipment of the
appliance and safeguard the appliance
against unintentional connection to the
circuit.
The gas supply and electrical cable must
be situated on the outside of the
radiation and combustion heat. Only use
heat-resistant cables near the tubes.
Electrical connection
Single stage operation
 Route the connection cable (power supply) to the
three-pin plug and connect the cables
(see Fig. 24, page 27).
 Plug in the three-pin plug into the socket of the
burner box.
 Connect the plug of the fan into the corresponding
socket at the burner box.


Pay attention of the correct polarity! If the
polarity is incorrect, the firing device will
not note any ionisation signal!
You find the three-pin socket for the
electrical supply on the burner box.
26
 Route the connection cable (power supply burner
unit) to the three-pin plug and connect the cables
(see Fig. 25, page 27).
 The connection cable of the modulation spool
connects by a branch box (see Fig.25, page 27).
 Plug in the three-pin plug into the socket of the
burner box.
 Connect the plug of the fan into the corresponding
socket at the burner box.

Start and ignition of the heater has
always to be in full load. After a time of
minimal 1 minute the heater can be
switched to small step.
You find the three-pin socket for the
electrical supply on the burner box. The
connection cable of the modulation spool
is screw on the gas combination valve.

Electrical connection
modulating operation
 Make sure that protective earth is connected
between modulation box and ThermoControl Plus M
controller.
 Route the connection cable (power supply burner
unit) from the modulation box to the three-pin plug
and connect the cables (see Fig. 26, page 28).
 Connect the connection cable for the lifting magnet
from the modulation box direct to the lifting magnet
modulating valve (see Fig.26, page 28).
 Plug in the three-pin plug into the socket of the
burner unit.
 Connect the plug of the fan into the corresponding
socket at the burner unit.

Start and ignition of the heater has
always to be in full load. After a time of
minimal 1 minute the heater can be
switched to small step.
You find the three-pin socket for the
electrical supply on the burner unit. The
connection cable of the lifting magnet is
screws on the modulating gas
combination valve.

Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
Danger of electric shock!
Electric shocks are highly dangerous!
Working at the electrical equipment of
the appliance is only allowed by
professional personnel observing the
current IEE regulations.
Electrical connection
two stage operation
infraSchwank D / calorSchwank D - shape U
Gas valve VK 4105C
1
Burner
unit
PE
2
L
PE
N
Control box
Thermocontrol Plus M /
unoSchwank
L
single-stage operation
N
PE
Electrical supply 1~230Volt, 50Hz, N, PE
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Fig. 24: Connecting diagram single-stage regulation infraSchwank D / calorSchwank D
Gas valve VK4115Q / VK 4105Q
with lifting magnet 2-stage
Burner
unit
1
PE
2
Connection box
Time delay 1minute
ignition for max. load
(integrated in control box
duoSchwank
and Thermocontrol Plus M)
L1
L2
N
PE
Control box
Thermocontrol Plus M /
duoSchwank
L1
two-stage operation
N
PE
Electrical supply 1~230Volt, 50Hz, N, PE
Fig. 25: Connecting diagram two-stage regulation infraSchwank D / calorSchwank D
27
infraSchwank D / calorSchwank D - shape U
GVK VK 4105N with
modulating lifting magnet
Burner
unit
1
PE
2
o
Modulation Box
(distance to burner unit < 1,5m)
PE
Time delay 1minute
ignition for max. load
(integrated in moduSchwank
and Thermocontrol Plus M)
L1
L2
N
PE
Control box
Thermocontrol Plus M /
moduSchwank
L1
N
P
Electrical supply 1~230Volt, 50Hz, N, PE
Fig. 26: Connecting diagram modulating operation infraSchwank D / calorSchwank D
Fig 27: Wiring diagram burner unit infraSchwank D / calorSchwank D
28
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
modulating operation
infraSchwank D / calorSchwank D - shape U
11 Commissioning
instructions
Before commissioning
Only authorised personnel can curry
out this operation.
The correct operation and fixing of the heater is
prerequisite for the warranty. Checking gas lines and
flue system is not included in this service.
Check the function of the following equipment:
 Exhaust flue
 Combustion air supply
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
 Control unit
 Safety equipment
 Safety of electrical circuit

Pay attention when commissioning!
Vaporization of remaining grease of
metal units may cause greasy mist.
This kind of mist disperses after
approx. 30 minutes. During this time
the room has to be ventilated.
Adjusting nominal thermal load at
single-stage operation
Attention!
The pressure control unit is preadjusted on natural gas / propane. Do
not put the appliance into operation
uncontrolled.
Adjusting the nozzle pressure
1. Open first the gas cock which is at the end of the
flexible gas hose (Fig.28, page 30).
2. Open the test nipple connection pressure.
Connect the pressure measuring instrument to the
test nipple and determine the connection
pressure.
Close the test nipple after the measurement!
3. Open the test nipple nozzle pressure.
Connect the pressure measuring instrument to the
test nipple to determine the connection pressure.
4. Remove the protection cap A (see Fig. 29,
page 30).
5. Put the radiant tube into operation.
6. Turn the adjusting screw on the pressure regulator
slowly in the “+” or “-” -direction while continuously
watching the pressure measuring instrument. Stop
turning as soon as the required nozzle pressure is
reached. The required nozzle pressure for natural
3
gas H (Wo,B =50.0 MJ/m ) or propane is shown in
table 5, page 18.
7. Put the protection cap A on the valve after the
adjusting.
8. Close the test nipple after the measurement
and check if the test nipple is gas-tight.
Checking adjustment
1. Turn the adjustment screw slightly to “-“
-direction. Nozzle pressure must drop
immediately. If this does not happen, you must
readjust the jet pressure until the point is reached
at which a decrease or increase in the nozzle
pressure is noticeable on the measuring
instrument.
2. Close test nipple after the measurement!
3. Remove the measuring instrument and check if
the test nipple is gas-tigh
29
infraSchwank D / calorSchwank D - shape U
Adjusting nominal thermal load
at two-stage operation
Fig 28:
A
B
Fig 30:
Adjusting screw nozzle pressure single stage
gas combination valve
D
E
Adjusting screw nozzle pressure with
lifting magnet two stage gas combination valve
Technical specification subject to change
Fig 29:
C
30
Gas cock with integrated TSD
Version 005 infra calor D shape U Australia 42/14
Adjusting the nozzle pressure
1. Open first the gas cock at the end of the flexible
gas hose (Fig.28, page 30).
2. Open the test nipple connection pressure.
Connect the pressure measuring instrument to the
test nipple and determine the connection
pressure.
Close the test nipple after the measurement!
3. Open the test nipple nozzle pressure.
Connect the pressure measuring instrument to the
test nipple to determine the nozzle pressure.
4. Take off the plastic cap E (see Fig. 30, page 30)
from the lifting magnet (lift the cap with a small
screw-driver)
5. Put the radiant tube into operation.
7. The electrical supply must activate for burner unit
and lifting magnet to adjust the nozzle pressure
of max. load. Turn the outer adjusting screw C
(width 8) slowly in the “+” or “-” -direction while
continuously watching the pressure measuring
instrument. Stop turning as soon as the required
nozzle pressure is reached The required nozzle
3
pressure for natural gas H (Wo,B =50.0 MJ/m ) or
propane is shown in table 5 page 18.
8. The electrical supply must activate only for the
burner unit to adjust the nozzle pressure of min.
load. Turn the inner adjusting screw D (screwdriver 6x1) slowly in the “+” or “-” -direction while
continuously watching the pressure measuring
instrument. Stop turning as soon as the required
nozzle pressure is reached.
9. Checking adjustment nozzle pressure as
described by the single stage performance.
10. Close test nipple after the measurement and
and check if the test nipple is gas-tight.
11.Put the plastic cap E on the lifting magnet.
infraSchwank D / calorSchwank D - shape U
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Adjusting thermal load
for modulating operation
Adjusting the nozzle pressure
1. Open first the gas cock which is at the end of the
flexible gas hose (Fig.28, page 30).
2. Open the test nipple connection pressure.
Connect the pressure measuring instrument to the
test nipple and determine the connection
pressure.
Close the test nipple after the measurement!
3. Open the test nipple nozzle pressure.
Connect the pressure measuring instrument to the
test nipple to determine the nozzle pressure.
4. The required nozzle pressure for natural gas H
3
(Wo,B =50.0 MJ/m ) or propane is shown in table
5, page 18.
4. Take off the plastic cap A (see Fig. 31, page 31)
from the lifting magnet.
5. Put the radiant tube into operation
In case a different value has to be set the output current
value in the Modulation Box has to be changed.
Please follow below mentioned procedure
[e.g. 0.87 / 0.6 kPa]:
7. Switch the jumper at the ThermoControl Plus M to
“Modulation”
8. Switch on the “Chimney sweeper” mode at the
ThermoControl Plus M
9. Ensure that the input pressure at the gas pressure
regulator is sufficient enough [e.g. 1.13kPa]
10.Push the “+/-“ button (button block “B”) so that the
measured nozzle pressure will be 0.1 kPa below the
required minimum value (e.g. 0.5 kPa).
If the value cannot be adjusted, the mechanical
limitation at the lifting magnet (large adjusting
screw B, Fig. 31) needs to be amended.
Afterwards continue with adjusting to the required
minimum value
11.To adjust the maximum pressure, the jumper has to
be switched to “Max”. With the “+/-“ buttons adjust
the value to 0.1 kPa above the required maximum
pressure (e.g. 0.88 kPa). In case the value cannot
be adjusted the mechanical limitation of the lifting
magnet (small adjusting screw C, Fig. 31) needs to
be amended. Afterwards continue with adjusting to
the required minimum value.
12. Check the minimum value again and re-switch the
jumper to “Min” position and adjust the value if
necessary (e.g. 0.5 kPa).
13. Adjustment of the mechanical pressure range of
the lifting magnet:
Place the jumper of the Modulation Box to the
“N” position. “Chimney sweeper” mode needs to
be still switched on. Disconnect the power
supply (clamp 7 / 8, Fig. 32) of the Modulation
Box or the connector of the lifting magnet.
Adjust the minimum value to the required nozzle
pressure (e.g. 0.6 kPa) at the lifting magnet.
Re-connect the electrical connection at the
Modulation Box (clamp 7 / 8) or the connector of
the lifting magnet and adjust the required
maximum value (e.g. 0.87 kPa) at the lifting
magnet.
14. Switch off the “chimney sweeper” mode.
15. Close test nipple after the measurement and and
check if the test nipple is gas-tight.
16. Put the plastic cap A on the lifting magnet
Fig. 31: Section of modulating lifting magnet
Fig. 32: Modulation Box
31
infraSchwank D / calorSchwank D - shape U
12 Service guide /
Trouble shooting
Maintenance and annual check
Any deviations must be fixed immediately. Defect
parts must be changed directly.
Pressure switches, pressure regulators, valves and
safety- and ignition devices can only be maintained
by the manufacturer or authorized personnel.
A regular maintenance is the requirement for a
faultless operation of the appliance.
According to the National Standard Regulations,
heating-systems with radiant tubes must be checked
at least once a year.
Maintenance and trouble shooting is only allowed by
professional personnel that is competent and
instructed in radiant tubes.
Trouble Shooting
fault
•
Fault in electrical supply
•
Thermostat "OFF"
•
Connection of ignition- and ionisation
electrode is wrong
•
Differential pressure switch is defect or
out of order (contact must be open)
Control goes in fault
position during prepurge period
•
Flame signal wrongfully caused by
electrical defect of control
•
Pressure differential is not sufficient
Control goes in fault
position during the
safety time
•
No flame (no ignition, valve doesn't
open, no gas)
•
No or poor flame signal (flame does not
stick, bad insulation of the flame
detector, no contact between burner
and earth connection)
•
W rong polarity
Control goes into
•
Flame is off
fault position during
operation
•
Contact of differential pressure switch
opens
Flame signal is poor
Burner does not start
Check the surface of radiant tubes

Check the pollution and sooting of tubes
 clean (if necessary)

Check tightness of the tube system including
connection to the burner unit

Check the air/flue-system  clean (if necessary)

Check the gas connection  Leakage-test

Check the connection pressure, nozzle pressure
and start step

Check gas filter in case of reduced line
pressure, in case of pollution change filter set

Check the safety functions of the ignition- and
ionisation-controls

Check the valve functions

Check the function of the pressure switch

Check the electrical connections

Check the slope of the tubes (3 mm/m in
direction of the turn around box connection)

Check the flexible gas hose and electrical
connection to the burner unit

Check the room temperature control

Check the distances to any flammable materials

Check the air/flue ventilation of the room

Remove condensation water in the tube

Check correct connection of the reflectors

Check if the fan impeller runs correctly and is
free of any damages

Check the tight fit of the fan venturi

Check connection and tightness of the fan to the
burner unit
32
•
In case of doubt, please contact:
Mr. John Balass
Devex Systems Pty Limited
5/83 Bassett St
Mona Vale NSW 2103
Tel: 02 9997 2811
Fax: 02 9997 7852
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
No gas (check pre- and nozzle
pressure)
Maintenance must include the following checks:

reason
•
infraSchwank D / calorSchwank D - shape U
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
13 Change of gas family
Fig 33: Change of gas family






Burner baffle (only 15 / 20 / 30 / 40U)
Instruction to adjust start step pressure
Burner cup
1.
Adjust the start step pressure with the regulation
screw, the pressure rise and the opening time
can be changed between set limits.
2.
The start step pressure must be set as the
specified values in tab 8. Turn it clockwise with a
screwdriver to increase the start step.
Burner nozzle
Regulation screw start step
Air baffle plate (only 15 / 20 / 30 / 40U)
Fan air restrictor
Instruction to change the gas family
1. Change the burner nozzle
2. Adjust the new nozzle pressure
(see tab. 5, page 18)
3. Adjust the new start step pressure
(see tab 8, page 33 )
infraSchwank D / calorSchwank D shape U
start step
gas
type
adjustment
pressure
regulation screw
[kPa]
15
30U
MIN
0.4
Natural
gas
40 U
MIN
0.3
Propane
15 - 40U
MAX
1.2
Tab 8: Setting regulation screw start step
4. Stick on the new rating label
33
infraSchwank D / calorSchwank D - shape U
14 Accessories
Ball guards
Ball protection grids acc.18032-3 for using heaters in
sport halls (grid 40x40mm).
Delivery scope
Mounting set complete for each type of heater
existing of:
infra/calorSchwank D shape U
15U
20U
30U
40U
2x
2x
Ball protection grid L=1443mm
Ball protection grid L=1843mm
2x
Ball protection grid L=2203mm
1x
Ball protection grid L=2963mm
1x
1x
2x
1x
1x
1x
1x
Front protection cover burner
1x
1x
1x
1x
Protection grid burner end side
1x
1x
1x
1x
End bracket with stud bolts M8
1x
1x
1x
1x
Holding bracket (1x infra D +1x calor D)
1x
1x
1x
Angled bracket with stud bolt M8
4x
4x
6x
8x
Clamp
6x
6x
8x
10x
Set fixing material
1x
1x
1x
1x
Assembling
(Description for heater infra/calorSchwank D 30 U,
other types similar)
5.
Assembling segments ball protection grids starts
on the turnaround box (last suspension bracket
for shape L). Put first segment ball protection
grid L=2963 mm from below on end bracket
and angled brackets of the next suspension
bracket – Put clamps on stud bolts M8 and
mount with self-locking nuts
Mount clamp loose on one stud bolt of angled
bracket for further assembling next protection
grid (Fig. 38, page 36).
6.
Put next segment ball protection grid
L= 1843mm from below on angled brackets and
mount clamp with self-locking nuts M8, clamp
and angled bracket connect two segments ball
protection grid to each other.
Mount clamp loose on one stud bolt of angled
bracket for further assembling next protection
grid.
7.
Put next segment ball protection grid
L= 1843mm from below on angled brackets and
mount clamps with self-locking nuts M8
Last segment ball protection grid L= 1843mm
protects the burner unit at the bottom.
1. Mounting heater as usually acc. manual
(see chapter 9, page 20 - 23).
2.
Fix end bracket at inner side of turnaround box,
open and close again 4 nuts M8
(Fig. 35, page 36)
3.
Fix two angled brackets at each tube hanger
(screws M8 x 60, nuts) (Fig. 36, page 36)
Screw on angled brackets at the inner holes of
suspension bracket.
4.
34
Holding bracket put loose on the first reflector
(view from burner unit) and screw together with
two angled brackets (screws M8 x 60, nuts),
holding bracket remain axially movable
NOTE: Use the right holding bracket –
difference infraSchwank D or calorSchwank D
– both in the delivery scope (Fig. 37, page 36)!
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
Protection grid burner top
infraSchwank D / calorSchwank D - shape U
8.
version stainlessAfter finish assembling of all
ball protection grids fix holding bracket with 3x
self-tapping screws on the reflector.
9.
Push on protection grid burner top from behind
over ball protection grid and burner up to the
suspension bracket. Note that the lower short
bending is on the left side in view from behind.
Fix burner protection grid burner top with
supplied cable straps or similar at bottom
protection grid.
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
10. Protection grid burner top has to be cut holes
depends on installation on-site for flue system
and may be gas line. Connect flue system pipes
and gas line.
NOTE: Select the cutouts large enough to
compensate the thermal length expansion of
the heater!
11. Insert front protection cover burner between
front cover plate reflector and burner unit and fix
it with supplied cable straps or similar on
protection grid burner top (Fig. 39, page 36).
12. Protection grid burner end side has to be cut
hole depends on installation on-site for gas line.
Fix with supplied cable straps or similar on
protection grid burner top.

Please note the required number and
length of segments ball protection grids
for each type of heater. Compare this to
the tabular and graphical overview.
Fig. 34: Overview of ball guards
35
infraSchwank D / calorSchwank D - shape U
Fig. 38: Loose mounted clamp
Fig. 36: Fixed angled bracket on suspension bracket
Fig. 39: Fixing front protection cover burner on protection
grid burner top
Holding bracket calor D shape U
Holding bracket infra D shape U
Fig. 37: Holding bracket infra D and calor D
36
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Fig. 35: Fixed end bracket on turnaround box
infraSchwank D / calorSchwank D - shape U
Reflector elongation
Set angled mounting tubes
Vertical elongation of reflectors b=415mm for thermal
protection. The numbers reflector elongation (single
sheets) is depend on required protection (one side
both side, protection length) and the power of the
radiant heater.
Bracket to ensure form and position of reflectors
when the heater is mounted angled (>15°). Bracket to
mount at each junction point reflector/reflector, not at
reflector end caps.
Delivery scope
Delivery scope
Reflector elongation consist of
 numbers of sheet reflector elongation
 mounting material
Mounting set consist of
 numbers of brackets
 mounting material
Assembling
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Assembling
1. Assembling and mounting tubes with reflectors
complete acc. manual (see chapter 9, page 20-23).
2. Fix screws with distance sleeve and mounting
angles A at hangers as required.
3. Mount end bracket B at turn around box.
4. Put reflector elongation sheet B on mounting
angle A. Screw both parts together with the
added clip C and screw/nut M8 and lock a nut to
ensure the reflector elongation sheets.
5. Fix reflector elongation sheets to another with
screw/nut M8.
1. Assembling and mounting of tubes complete
(without reflectors) acc. manual
(see chapter 9, page 20-23).
2. Lay first reflector on turn around box and first
hanger, fix it at turn around box with two screws.
3. Fix angled bracket D with screws and nuts M8 at
first hanger, bracket under reflector.
4. Put on next reflector, reflectors are fixed to
another by 3 screws/nuts M5, middle screw
through angled bracket.
5. Further assembling as usually acc. to manual.

At heaters with axial reflector elongation
the last suspension bracket on the
burner side must be mounted at the
junction point reflector/reflector end
plate.
D
D
A
C
B
C
Fig 40, 41: Assembling order reflector elongation
Fig 42, 43: Assembling order set angled mounting
37
infraSchwank D / calorSchwank D - shape U
Water protection cover
Protection cover of the burner unit 15-40U with
electrical protection class IP 55 against water or
aggressive mediums, cover complete in stainless steel.
In delivery scope a mounting set existing of:
 Protection cover with inlet air adapter
(premounted and sealed),
hinged cover plate and premounted surrounding
rubber seal
 Gas inlet connection with union fitting (premounted)
 Gasket for mounting water protection cover and
radiant tube
Assembly instruction
Divide gas inlet connection at the union fitting
2.
Install with sealant the half of the divided gas inlet
connection with coupling fitting to male thread gas
connection burner unit.
Note 40kW: First replace reducing nipple
¾“x ½“ from burner unit!
3.
Mount complete burner including burner baffle into
protection box, front fixing bolt at burners flange
reaches through front of the protection box.
4.
Pass other half gas inlet connection through PG
gland and connect with burner unit. Union fitting
first tighten by hand.
5.
Stick gasket on protection box with silicon. Mount
complete protection box with burner unit inside at
radiant tube flange with gasket between tube
flange and protection box. Fix front fixing bolt of the
burner unit tight with flange radiant tube.
6.
Tighten union fitting of the gas inlet connection
with tool.
7.
Assemble electrical connection through PG grand
and connect with device plug, if necessary pass
cable for 2-stage or modulating regulation through
the second PG grand.
8.
Fit tight the counter nuts of all PG glands.
9.
Connect the heater with an approved flexible gas
hose.
Note 40kW: Mount reducing nipple
¾“x ½“on outer thread gas inlet connection
with sealant!
10. Start tube heater, check gas pressures.
11. Close cover plate water protection box with two
wing screws.
38
Fig. 44: Mounted burner unit in protection cover with
gas inlet and electrical connections
Fig. 45: Complete mounted and closed water protection cover
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
1.
infraSchwank D / calorSchwank D - shape U
Gas filter - groups
To avoid technical problems with the gas combination
valves which are caused by pollution of dust or rust
coming out of the gas pipe should to be mounted a
gas filter-group ¾“ (gas filter + premounted double
nipple) for tube heater 40U.
For tube heaters 15-30U a similar gasfilter-group
½“ has to be ordered in case the gas pipe is made of
black steel (welded).
gas filter-group Rp ½“
for 15-30U
gas filter-group Rp 3/4“
for 40U
code no: 192 0756 0
code no: 192 0757 9
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Assembly instruction
Direct installation between flexible gas pipe and valve
burner unit, with a slight radial slope for better cleaning
the filter bottom! In case of strong polluted filter pad use
the corresponding spare part set for gas filter.
Pay attention to the flow direction of the filter!
Fig 46: Mounted gas filter-group at tube heater
39
infraSchwank D / calorSchwank D - shape U
15 Spare parts
 
 








Fig. 47: Spare parts infra D / calor D 20U
Pos. Part
1
Art.-No.
Burner unit infra D / calor D 15 Natural gas
126 7165 0
Burner unit infra D / calor D 20 Natural gas
126 7151 0
Burner unit infra D / calor D 30 Natural gas
126 7153 0
Burner unit infra D / calor D 40 Natural gas
126 7155 0
2
Radiant tube L 3050mm infra D / calor D (not in figure 42)
126 7020 0
3
Radiant tube L 3050mm with turbulator infra D / calor D (not in figure 42)
126 7055 0
4
Radiant tube L 4540mm infra D / calor D
126 4722 0
5
Radiant tube L 4540mm infra D / calor D with turbulator
126 7056 0
6
Radiant tube L 5950mm infra D / calor D (not in figure 42)
126 7199 0
7
Radiant tube L 5950mm stainless steel with welded flanges (not in figure 42)
126 7220 0
8
Radiant tube L 3050mm with burner flange (not in figure 42) [only for heringbone systems]
126 7069 0
9
Radiant tube L 4540mm with burner flange (not in figure 42) [only for heringbone systems]
126 7070 0
10
Radiant tube L 5950mm with burner flange (not in figure 42) [only for heringbone systems]
126 7408 0
11
Gasket between tubes and burner infra D / calor D
126 7048 0
12
Turnaround box
126 7015 0
13
Reflector infra D shape U (L 3000mm)
126 7011 0
14
Reflector calor D shape U (L 3000mm)
126 7062 0
15
Reflector short infra D 20U (L 1500mm)
126 7221 0
16
Reflector short calor D 20U (L 1500mm)
126 7234 0
17
Suspension bracket infra D / calor D shape U
126 7012 0
18
Tube bar
126 4529 5
19
Mounting set infra D / calor D 15U (not in figure 42)
126 7102 0
20
Mounting set infra D / calor D 20U (not in figure 42)
126 7129 0
21
Mounting set infra D / calor D 30U (not in figure 42)
126 7103 0
22
Mounting set infra D / calor D 40U (not in figure 42)
126 7116 0
40
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
Spare parts infra D / calor D 15-40U
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
infraSchwank D / calorSchwank D - shape U
Fig. 48: Spare parts burner unit
Spare parts burner unit infra D / calor D 15-40U
Pos.
Part
Art.-No.
1
Spark igniter with ionisation cable
127 0246 9
2
Ignition wiring with plug
126 7021 0
3
Controller Microgas P25
126 7495 0
4
Pressure switch DL1E with damping nozzle
192 0217 8
5
Spare part gas valve cpl. premounted – replacement HONEYWELL for SIT
infra D / calor D 15-40U / 1-stage with cable valve – in cardboard
126 7532 1
6
Spare part gas valve cpl. premounted - replacement HONEYWELL for SIT 2-stage / Natural gas
infra D / calor D 15-40U / with cable for valve and 2-stage coil – in cardboard
126 7536 1
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Spare part gas valve cpl. premounted - replacement HONEYWELL for SIT 2-stage / Propane
infra D / calor D 15-40U / with cable for valve and 2-stage coil – in cardboard
Connection cable lifting magnet modulating valve (not in figure 43)
Spare part gas valve HONEYWELL for HONEYWELL 1-stage VK 4105C
Spare part gas valve HONEYWELL for HONEYWELL 2-stage / Natural gas VK 4115Q 2004
Spare part gas valve HONEYWELL for HONEYWELL 2-stage / Propane VK 4105Q 2010
Spare part gas valve HONEYWELL for HONEYWELL modulating / Natural gas VK 4105N 2005
Spare part gas valve HONEYWELL for HONEYWELL modulating / Propane VK 4105N 2054
Burner cup aluminum complete infra D / calor D 15-30U
Burner cup steel complete infra D / calor D 40U Natural gas
Fan complete with venturi infra D / calor D 15-40U with transport lock - in cardboard
Gas filter complete ½“ (for infra D / calor D 15–30U) (not in figure 43)
Gas filter complete ¾“ (for infra D / calor D 40U)(not in figure 43)
Spare part kit for gas filter ½“ (not in figure 43)
Spare part kit for gas filter ¾“ (not in figure 43)
126 7536 2
169 1019 0
192 0765 0
192 0766 0
192 0766 1
192 0761 2
192 0761 0
126 7239 0
126 7219 0
126 7684 0
192 0756 0
192 0757 9
192 0758 0
192 0759 0

The reducing nipple reducing nipple ¾” to ½” installed on site for heaters 40U has to be used
again (position 5-7).
41
infraSchwank D / calorSchwank D - shape U
16 AGA Certification
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
42
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
infraSchwank D / calorSchwank D - shape U
17 EC type examination certificate
43
infraSchwank D / calorSchwank D - shape U
Version 005 infra calor D shape U Australia 42/14 Technical specification subject to change
44
Version 005 infra_calor D shape U Australia 42/14 Technical specification subject to change
infraSchwank D / calorSchwank D - shape U
18 EC declaration of
conformity
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