Installation/Commissioning/Maintenance/User instructions

Direct Fired air handling unit

These appliances meet the following EC Directives:

DIR 009/142/EC:GAD

DIR2004/108/EC:EMC

DIR 2006/95/EC: LVD

DIR 89/392/EEG:MD

Please read this document carefully before commencing the installation and leave it with the user or attached to the appliance or gas service meter after installation!

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. All work must be carried out by appropriately qualified persons.

The manufacturer does not take any responsibility in the event of non-observance of the regulations concerning the connection of the apparatus causing an evil operation possibly resulting in damage to the apparatus and/or environment in which the unit is installed.

Subject to modifications

Reznor Europe N.V.

J.&M. Sabbestraat 130/A000 - B 8930 Menen

Tel : +32 56 529 511

Fax : +32 56 529 533

E-mail: [email protected] www.reznor.eu

INDEX Section

Introduction ----------------------------------------------------------------------- 1

General Requirements -------------------------------------------------------- 2

Ventilation Requirements ----------------------------------------------------- 3

Technical Data ------------------------------------------------------------------ 4

Installation Details -------------------------------------------------------------- 5

Commissioning & Testing ---------------------------------------------------- 6

Servicing -------------------------------------------------------------------------- 7

Troubleshooting ----------------------------------------------------------------- 8

Parts Removal & Replacement --------------------------------------------- 9

Spare Parts -------------------------------------------------------------------- 10

User & Operating Instructions ----------------------------------------------11

WARNINGS

1 This appliance must only be installed by a competent person in accordance with the requirements of the Codes of Practice or the rules in force.

2 All external wiring MUST comply with the current IEE wiring regulations.

3 Warning this appliance must be earthed.

2

1. Introduction.

1: Introduction

The Reznor Europe DF Direct Fired air handling

Heater casing

The heater casing comprises of an aluminium range is designed for economical and efficient Pentapost frame construction mounted onto a operation to give clean and healthy environmental conditions, with constant even temperature control. It is available either as a

DF MUA – make up air unit or,

DF VAV – variable air volume unit. can be either pre-insulated 25mm thick (or

50mm optional) expanded polyurethane foam or single outer skin, coated steel/aluzinc/ galvanised, or outer skin coated steel/aluzinc/

DF MUA galvanised with rockwool or melamine foam insulation, with an option of an inner galvanised

MUA heaters are fitted with a double inlet skin. The casing incorporates an internal burner distribution head or in conjunction with duct work. The heater has no heat exchanger, all the products of combustion being discharged into the heated space, thus no flue is necessary. steel angle supports.

The unit is fitted with hinged access panel doors in the side of the heater for internal inspection of the fan, motor and burner module.

The heater is fitted with the Reznor Europe

The heater air fan, motor and drive belts are fitted inside the heater casing on the standard NG2 burner (see diagram 7) and downstream side of the burner and incorporate profile plate which as been specially designed anti-vibration mounts. so that a proportion of the incoming air is forced into contact with the flame to ensure rapid Control system mixing with uniform heating to the desired The control of the heater is carried out by the temperature and allows a high turn-down. The dictates of the building management system or burner is fully modulating which provides the approved controls, specified in the wiring diaoptimum heat required at maximum efficiency, gram. so reducing running costs. Typical control sequence:

DF VAV

VAV heaters are fitted with a double inlet

DF MUA control sequence

Outside occupancy times the space is protected multivane fan. It may be free blowing into a by a frost set point. If the space temperature distribution head or in conjunction with duct falls below the desired frost set point, the heater work. The heater has no heat exchanger, all the will start up and will operate at maximum products of combustion being discharged into discharge temperature to achieve a rapid heat the heated space, thus no flue is necessary. up time. Once the space temperature rises above the frost set point the heater will shut

The heater is fitted with the Reznor Europe box down. burner with NG1 burner (see diagram 6), During occupancy times the space temperature replacing the standard NG2 and profile plate is controlled to the occupied set point. If the arrangement giving similar combustion properties but with the advantage of providing its set point, the heater will operate at maximum own combustion air. The air flow through the discharge temperature to achieve a rapid heat heater is controlled by an inverter connected to up time. As the space temperature approaches the main fan motor. Various types of inputs can set point the discharge temperature set point will be fed into the microprocessor controller varying begin to reduce, this reduction in temperature the air volume of the unit for a variety of continue as long as the space applications. temperature continues to rise until the minimum discharge set point temperature is

Gas burner assembly reached. At 1˚C above room set point the components to give the required heat duty. The burner consists of a heavy duty iron body which run, if space temperature falls below 0.5˚C below set point the burner will restart and operforms the fuel gas manifold, fitted with stainless ate as described above. steel mixing plates carefully designed to Operation can be varied to suit site conditions. withstand the stresses of thermal expansion.

The mixing plates are perforated to ensure DF VAV control sequence intimate and progressive mixing of the incoming

Outside occupancy times the space is protected air with the fuel gas at all firing rates. by a frost set point. If the space temperature falls below the desired frost set point, the heater will start up and will operate at maximum speed

3

1. Introduction cont.

and at maximum discharge temperature to achieve a rapid heat up time. Once the space temperature rises above the frost set point the heater will shut down.

During occupancy times the space temperature is controlled to the occupied set point. If the space temperature is below the desired room set point, the heater will operate at maximum speed and discharge temperature to achieve a

Overheat

In the event of an over-heat condition, within the heater casing, the heater is fitted with over temperature protection, which has to be manually reset if activated. Indication may be given by an amber lamp on the control panel.

(See wiring diagram)

Safety interlocks approaches 1˚C below room set point the fan will begin to reduce in speed whilst discharging interlocks:

1. Low air differential pressure switch. temperature. The fan speed will continue to 3. Lockout on flame failure/or air pressure decrease as the space temperature rises until it failure. has reached its minimum speed setting. As the space temperature approaches set point the Site wiring discharge temperature will begin to reduce, this

Site wiring requires the connection of: reduction in temperature will continue as long as

1. 415v TPN + E or 230v 1PN + E 50Hz the space temperature continues to rise until the supply to the main heater control panel (refer to minimum discharge set point temperature is wiring diagram) reached. At 0.5˚C above room set point the

2. Data cable between heaters, where heater will shut down, if space temperature falls applicable. below 0.5˚C below set point the heater will 3. Duct sensor, room sensor and outside air restart and operate as described above. If the sensor. space temperature increases to more than the

4. External interlocks where applicable. room set point plus the customer set vent differential (adjustable 0-15˚C) the fan only will Fuel supply system start at low speed to bring fresh air into the

1: Start gas supply line (if applicable) room. This speed will gradually ramp up if the

The start gas line comprises : room temperature increases. a. Inlet gas isolating valve.

Operation can be varied to suit site conditions.

The purge, ignition and main flame stages of the b. Gas governor.

Control panel

Burner sequence c. Class A approved solenoid valves. d. Gas isolating valves.

The heater control panel incorporates a Satronic flame programmer, necessary e. Pipework, fittings and pressure test points.

2: Main gas train contactors, relays, indication lamps, illuminated

The main gas train comprises push button etc. all pre-wired to a terminal rail. a. Inlet gas isolating valve. b. Combined gas governor, safety shut off valves and strainer. c. Motorised control ball valve. burner are controlled via a Satronic approved d. Burner isolating valve. flame programmer. e. Pipework, fittings and pressure test points.

2. General Requirements.

Related documents

The installation of the Reznor Europe direct gas fired air heater must be in accordance with the relevant provisions of the Gas Safety

(installations and use) Regulations 1998. Due account should also be taken of any obligations

the following documents:

British standards

BS EN 525:1998

Non-domestic direct gas fired forced convection air heaters for space heating not exceeding a net heat input of 300 kW. arising from the Health and Safety at Work act

1974, building regulations, and the current

BS6230:2005

Specification for installation of gas fired forced edition of the IEE wiring regulations.

It should also be in accordance with any convection air heaters for commercial and relevant requirements of the local gas supplier, industrial space heating (2 nd and 3 rd family the local authority, the current IGEM technical gases). standards and the relevant recommendations of

4

3. Ventilation Requirements.

Guidance for limitations of application of direct fired air heaters in buildings.

The examples given below are for achieving a

MAC limit value of 5000 x 10

-6

CO

2

, reference gas G20. In the case of other limit values to suit heater or heaters and ventilation facilities of the space or spaces to be supplied with the heated air, shall be designed and operated such that national MAC levels and different gas categories, extrapolation is necessary.

General requirements.

Where vapour and/or gases or airborne dusts are present which degrade to products that are potentially harmful to health when passed through the combustion zone of a flame, all the air to a direct fired air heater shall be outside air. where the air is likely to be inhaled by persons present shall not exceed 0.28% (V/V)

(2800 x

10-6

). This level may differ, depending on local requirements.

Assessment of concentrations.

The specified maximum concentration of carbon dioxide can be assessed from the table below:

Recirculation, if practised shall be downstream of the burner combustion zone.

Safe operating emission levels.

The total installation, that is the combination of

Designation of gas G 20 G 25 G 31

V air required to limit CO

2 concentration (0.28% m

3

)

37.80 36.34 46.30

NOTE: The above assumes fresh air contains 0.03% CO

2

The following simplified equation is used to calculate the heat requirement, H, (in mJ/h) of the incoming air:

H = A x V x C v x T x 10

-3

Where:

A is the number of air changes per hour.

V is the room volume in cubic metres.

C v is the heat capacity, volume basis, of air.*

T is the temperature difference in kelvins.

* The specific heat of air as (1207 kJ/m

3

K)

5

4. Technical Data (Natural Gas G20 & G25).

MODEL

RANGE

STD

BURNER

VAV

BURNER

BTU/Hr BURNER

REF

FAN SIZE GROSS HEAT

INPUT kW

NET HEAT

INPUT kW

HEAT

OUTPUT kW

GAS

RATE m³/ Hr

DF1 DF1MUA30 DF1VAV30 100000

DF2MUA50 DF2VAV50 200000

DF2

DF2MUA75 DF2VAV75 250000

DF3

DF3MUA50

DF3MUA75

DF3VAV50

DF3VAV75

DF3MUA150 DF3VAV150

200000

250000

500000

DF4

DF5

DF7

DF9

DF4MUA75 DF4VAV75

DF4MUA100 DF4VAV100

DF4MUA150 DF4VAV150

DF4MUA220 DF4VAV220

250000

350000

500000

750000

DF5MUA150 DF5VAV150

DF5MUA220 DF5VAV220

500000

750000

DF5MUA300 DF5VAV300 1000000

DF7MUA220 DF7VAV220 750000

DF7MUA300 DF7VAV300 1000000

DF7MUA375 DF7VAV375 1250000

DF9MUA300 DF9VAV300 1000000

DF9MUA450 DF9VAV450 1500000

DF9MUA500 DF9VAV500 1750000

DF11MUA300 DF11VAV300 1000000

DF11MUA375 DF11VAV375 1250000

DF11

DF11MUA500 DF11VAV500 1750000

DF11MUA650 DF11VAV650 2250000

DF14MUA450 DF14VAV450 1500000

DF14MUA600 DF14VAV600 2000000

DF14 DF14MUA650 DF14VAV650 2250000

DF14MUA725 DF14VAV725 2500000

DF14MUA800 DF14VAV800 2750000

DF18MUA600 DF18VAV600 2000000

DF18MUA800 DF18VAV800 2750000

DF18

DF18MUA875 DF18VAV875 3000000

DF18MUA1000 DF18VAV1000 3500000

DF25MUA650 DF25VAV650 2250000

DF25MUA725 DF25VAV725 2500000

DF25

DF25MUA800 DF25VAV800 2750000

DF25MUA875 DF25VAV875 3000000

DF25MUA1000 DF25VAV1000 3500000

DF25MUA1175 DF25VAV1175 4000000

900

900

900

900

800

800

800

800

800

1000

1000

1000

1000

1000

1000

710

710

710

710

560

630

630

630

500

500

500

560

560

400

400

400

400

180

250

250

355

355

355

48

66

72

84

36

48

54

60

66

54

60

66

72

84

96

24

30

42

54

30

24

36

42

12

18

24

18

24

6

12

12

18

6

6

6

6

6

12

439.62

586.17

659.44

732.71

805.98

586.17

805.98

879.25

1025.79

366.35

293.08

439.62

512.90

293.08

366.35

512.90

659.44

659.44

732.71

805.98

879.25

1025.79

1172.33

73.27

102.58

146.54

219.81

146.54

219.81

293.08

219.81

293.08

29.31

58.62

73.27

58.62

73.27

146.54

396.06

528.08

594.09

660.10

726.11

528.08

726.11

792.12

924.14

330.05

264.04

396.06

462.07

264.04

330.05

462.07

594.09

66.01

92.41

132.02

198.02

132.02

198.03

264.04

198.03

264.04

26.40

52.81

66.01

52.81

66.01

132.02

594.09

660.10

726.11

792.12

594.09

660.10

726.11

792.12

924.14 924.14

1056.16 1056.16

63.41

70.45

77.50

84.54

98.63

112.72

66.01

92.41

132.02

198.02

132.02

198.03

264.04

198.03

264.04

26.40

52.81

66.01

52.81

66.01

132.02

396.06

528.08

594.09

660.10

726.11

528.08

726.11

792.12

924.14

330.05

264.04

396.06

462.07

264.04

330.05

462.07

594.09

7.05

9.86

14.09

21.14

14.09

21.14

28.18

21.14

28.18

2.82

5.64

7.05

5.64

7.05

14.09

42.27

56.36

63.41

70.45

77.50

56.36

77.50

84.54

98.63

35.23

28.18

42.27

49.32

28.18

35.23

49.32

63.41

6

MODEL

RANGE

4. Technical Data (Natural Gas G20 & G25) cont.

STD

BURNER

VAV

BURNER

GAS INLET

CONNEC-

TION

BSP

INLET GAS

PRESSURE

(mbar)

G20

NG 2 STD

BURNER

DIFF

PRESSURE

(mbar)

G20

NG 1 VAV

BURNER

DIFF

PRESSURE

(mbar)

G25

NG 2 STD

BURNER

DIFF

PRESSURE

(mbar)

G25

NG 1 VAV

BURNER

DIFF

PRESSURE

(mbar)

MINIMUM MAXIMUM

AIR RATE AIR RATE m³/sec m³/sec

DF1 DF1MUA30 DF1VAV30

DF2MUA50 DF2VAV50

DF2

DF2MUA75 DF2VAV75

DF3

DF4

DF3MUA50

DF3MUA75

DF3VAV50

DF3VAV75

DF3MUA150 DF3VAV150

DF4MUA75 DF4VAV75

DF4MUA100 DF4VAV100

DF4MUA150 DF4VAV150

DF4MUA220 DF4VAV220

½¨

½¨

½¨

½¨

½¨

¾¨

½¨

¾¨

¾¨

1¨

17

17

17

17

17

17

17

17

17

17

1.0

3.8

6.0

3.8

6.0

6.0

6.0

2.9

6.0

6.0

1.9

7.5

11.7

7.5

11.7

11.7

11.7

5.7

11.7

11.7

1.5

5.5

8.7

5.5

8.7

8.7

8.7

4.2

8.7

8.7

2.8

10.9

17.0

10.9

17.0

17.0

17.0

8.3

17.0

17.0

0.51

1.03

1.28

1.54

1.80

2.57

2.16

2.52

2.57

3.85

0.86

1.72

2.16

1.72

2.16

3.08

2.51

3.02

3.85

4.37

DF5

DF7

DF9

DF11

DF14

DF18

DF25

DF5MUA150 DF5VAV150

DF5MUA220 DF5VAV220

DF5MUA300 DF5VAV300

DF7MUA220 DF7VAV220

DF7MUA300 DF7VAV300

DF7MUA375 DF7VAV375

DF9MUA300 DF9VAV300

DF9MUA450 DF9VAV450

DF9MUA500 DF9VAV500

DF11MUA300 DF11VAV300

DF11MUA375 DF11VAV375

DF11MUA500 DF11VAV500

DF11MUA650 DF11VAV650

DF14MUA450 DF14VAV450

DF14MUA600 DF14VAV600

DF14MUA650 DF14VAV650

DF14MUA725 DF14VAV725

DF14MUA800 DF14VAV800

DF18MUA600 DF18VAV600

DF18MUA800 DF18VAV800

DF18MUA875 DF18VAV875

DF18MUA1000 DF18VAV1000

DF25MUA650 DF25VAV650

DF25MUA725 DF25VAV725

DF25MUA800 DF25VAV800

DF25MUA875 DF25VAV875

DF25MUA1000 DF25VAV1000

DF25MUA1175 DF25VAV1175

2¨

2¨

2¨

2¨

2¨

2¨

2¨

2¨

2¨

1½¨

2¨

2¨

2¨

2¨

2¨

1¼¨

1½¨

1½¨

1¼¨

1½¨

1½¨

2¨

¾¨

1¨

1¼¨

1¨

1¼¨

1½¨

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

17

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

8.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

11.7

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

7

6.0

7.07

7.70

8.98

8.62

8.98

8.98

11.55

4.07

4.09

5.13

5.05

5.13

6.42

10.11

10.27

11.55

12.83

14.12

13.47

14.12

15.40

17.96

17.96

18.91

20.44

20.86

20.96

20.53

7.70

8.08

9.09

8.62

10.78

11.43

11.55

4.31

4.31

5.13

5.39

5.99

7.09

12.93

13.07

12.44

13.47

14.12

14.14

15.60

17.02

18.18

19.40

20.73

21.96

23.95

24.34

26.13

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

4. Technical Data (Propane G31).

MODEL

RANGE

STD

BURNER

VAV

BURNER

BTU/Hr BURNER

REF

FAN SIZE GROSS HEAT

INPUT kW

NET HEAT

INPUT kW

HEAT

OUTPUT kW

GAS

RATE kg/ Hr

DF1 DF1MUA30 DF1VAV30 100000

DF2MUA50 DF2VAV50 200000

DF2

DF2MUA75 DF2VAV75 250000

DF3

DF3MUA50

DF3MUA75

DF3VAV50

DF3VAV75

DF3MUA150 DF3VAV150

200000

250000

500000

DF4

DF5

DF7

DF9

DF4MUA75 DF4VAV75

DF4MUA100 DF4VAV100

DF4MUA150 DF4VAV150

DF4MUA220 DF4VAV220

250000

350000

500000

750000

DF5MUA150 DF5VAV150

DF5MUA220 DF5VAV220

500000

750000

DF5MUA300 DF5VAV300 1000000

DF7MUA220 DF7VAV220 750000

DF7MUA300 DF7VAV300 1000000

DF7MUA375 DF7VAV375 1250000

DF9MUA300 DF9VAV300 1000000

DF9MUA450 DF9VAV450 1500000

DF9MUA500 DF9VAV500 1750000

DF11MUA300 DF11VAV300 1000000

DF11MUA375 DF11VAV375 1250000

DF11

DF11MUA500 DF11VAV500 1750000

DF11MUA650 DF11VAV650 2250000

DF14MUA450 DF14VAV450 1500000

DF14MUA600 DF14VAV600 2000000

DF14 DF14MUA650 DF14VAV650 2250000

DF14MUA725 DF14VAV725 2500000

DF14MUA800 DF14VAV800 2750000

DF18MUA600 DF18VAV600 2000000

DF18MUA800 DF18VAV800 2750000

DF18

DF18MUA875 DF18VAV875 3000000

DF18MUA1000 DF18VAV1000 3500000

DF25MUA650 DF25VAV650 2250000

DF25MUA725 DF25VAV725 2500000

DF25

DF25MUA800 DF25VAV800 2750000

DF25MUA875 DF25VAV875 3000000

DF25MUA1000 DF25VAV1000 3500000

DF25MUA1175 DF25VAV1175 4000000

900

900

900

900

800

800

800

800

800

1000

1000

1000

1000

1000

1000

710

710

710

710

560

630

630

630

500

500

500

560

560

400

400

400

400

180

250

250

355

355

355

48

66

72

84

36

48

54

60

66

54

60

66

72

84

96

24

30

42

54

30

24

36

42

12

18

24

18

24

6

12

12

18

6

6

6

6

6

12

439.62

586.17

659.44

732.71

805.98

586.17

805.98

879.25

1025.79

366.35

293.08

439.62

512.90

293.08

366.35

512.90

659.44

659.44

732.71

805.98

879.25

1025.79

1172.33

73.27

102.58

146.54

219.81

146.54

219.81

293.08

219.81

293.08

29.31

58.62

73.27

58.62

73.27

146.54

31.40

41.87

47.10

52.34

57.57

41.87

57.57

62.80

73.27

47.10

52.34

57.57

62.80

73.27

83.74

26.17

20.93

31.40

36.64

20.93

26.17

36.64

47.10

5.23

7.33

10.47

15.70

10.47

15.70

20.93

15.70

20.93

2.09

4.19

5.23

4.19

5.23

10.47

403.33

537.77

604.99

672.21

739.43

537.77

739.43

806.65

941.09

336.10

268.88

403.33

470.55

268.88

336.10

470.55

604.99

604.99

672.21

739.43

806.65

604.99

672.21

739.43

806.65

941.09 941.09

1075.53 1075.53

336.10

268.88

403.33

470.55

268.88

336.10

470.55

604.99

403.33

537.77

604.99

672.21

739.43

537.77

739.43

806.65

941.09

67.22

94.11

134.44

201.66

134.44

201.66

268.88

201.66

268.88

26.89

53.78

67.22

53.78

67.22

134.44

67.22

94.11

134.44

201.66

134.44

201.66

268.88

201.66

268.88

26.89

53.78

67.22

53.78

67.22

134.44

8

4. Technical Data (Propane G31) cont.

MODEL

RANGE

STD

BURNER

VAV

BURNER

GAS INLET

CONNEC-

TION

BSP

INLET GAS

PRESSURE

(mbar)

NG 2 STD

BURNER

DIFF

PRESSURE

(mbar)

NG 1 VAV

BURNER

DIFF

PRESSURE

(mbar)

MINIMUM MAXIMUM

AIR RATE AIR RATE m³/sec m³/sec

DF1 DF1MUA30 DF1VAV30

DF2MUA50 DF2VAV50

DF2

DF2MUA75 DF2VAV75

½¨

½¨

½¨

37

37

37

0.5

1.5

2.5

1.0

2.9

4.9

0.52

1.05

1.31

0.88

1.76

2.20

DF3

DF4

DF5

DF7

DF9

DF11

DF14

DF18

DF25

DF3MUA50

DF3MUA75

DF3VAV50

DF3VAV75

DF3MUA150 DF3VAV150

DF4MUA75 DF4VAV75

DF4MUA100 DF4VAV100

DF4MUA150 DF4VAV150

DF4MUA220 DF4VAV220

DF5MUA150 DF5VAV150

DF5MUA220 DF5VAV220

DF5MUA300 DF5VAV300

DF7MUA220 DF7VAV220

DF7MUA300 DF7VAV300

DF7MUA375 DF7VAV375

DF9MUA300 DF9VAV300

DF9MUA450 DF9VAV450

DF9MUA500 DF9VAV500

DF11MUA300 DF11VAV300

DF11MUA375 DF11VAV375

DF11MUA500 DF11VAV500

DF11MUA650 DF11VAV650

DF14MUA450 DF14VAV450

DF14MUA600 DF14VAV600

DF14MUA650 DF14VAV650

DF14MUA725 DF14VAV725

DF14MUA800 DF14VAV800

DF18MUA600 DF18VAV600

DF18MUA800 DF18VAV800

DF18MUA875 DF18VAV875

DF18MUA1000 DF18VAV1000

DF25MUA650 DF25VAV650

DF25MUA725 DF25VAV725

DF25MUA800 DF25VAV800

DF25MUA875 DF25VAV875

DF25MUA1000 DF25VAV1000

DF25MUA1175 DF25VAV1175

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5

1.5

2.5

2.5

2.5

1.5

2.5

2.5

2.5

2.5

1½¨

1½¨

1½¨

1¨

1¨

1½¨

1½¨

1½¨

1½¨

¾¨

¾¨

1¨

1¨

1½¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

¾¨

1¨

½¨

½¨

½¨

¾¨

½¨

½¨

½¨

½¨

¾¨

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

4.9

2.9

4.9

4.9

4.9

2.9

4.9

4.9

4.9

4.9

9

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

37

14.37

15.68

18.29

11.76

13.07

14.37

15.68

18.29

20.91

7.84

10.45

11.76

13.07

14.37

10.45

5.23

3.92

5.23

6.53

5.23

7.84

9.15

1.05

1.31

2.61

1.31

1.83

2.61

3.92

2.61

3.92

5.23

6.53

9.15

11.76

15.89

17.33

18.52

19.76

21.11

22.36

23.52

24.79

26.61

13.17

13.31

12.67

13.72

14.37

14.40

5.23

5.49

6.10

7.22

7.84

8.23

9.26

1.76

2.20

3.14

2.55

3.07

3.92

4.45

4.39

4.39

8.78

10.98

11.64

11.76

4. Technical Data cont.

Options

 Available in horizontal or vertical orientation denoted by H or V.

 Available as internal as standard or with weather kit for external use denoted by EX.

 Available with options such as filters (bag, panel) and silencers.

 Available with different motors to suit a range of ESPs from 50 to 1000 Pa.

 Available without a fan as a duct package denoted by DP after the range number such as DF5DPVAV150.

 Available without a fan and with a frame for fitting inside customers AHU denoted by AH after the range number such as DF5AH150.

 The maximum temperature rise through the unit is 42˚C based on minimum air rate.

Diagram 1: Clearances required for maintenance

(Generic heater shown for illustration purposes)

1000mm (access side)

500mm (above)

500mm (non- access side)

10

4. Technical Data cont.

Diagram 2: Horizontal units (VAV model shown) See diagrams 6 and 7 for burner details.

Fan/motor assembly

Burner assembly

Weatherhood assembly

(optional external units only)

Air outlet

PLAN VIEW

Fresh air inlet

Panel, bag & panel, or V filter assembly

(optional)

Control cubicle assembly

DIM C

Air outlet

Fresh air inlet

Top & bottom outlet also available

SIDE VIEW (ACCESS)

Table1:Horizontal unit dimensions

Model

Range

A B C

No filter

Panel+

V filter

DIM B

DF9/11 1900 3840

REAR VIEW (INLET)

DF18/25 2350 2600 3500 4140

Horizontal units are denoted the letter 'H' inserted after the model No. such as: DF5VAV150H. If the unit is also for external use, (with optional weatherkit) the letters 'EX' should be included at the end of the model No. such as: DF5VAV150HEX.

11

4. Technical Data cont.

Diagram 3: Vertical units (VAV model shown)

See diagrams 6 and 7 for burner details

Fan/motor assembly

Air outlet

Side outlet shown,

top outlet also available

FRONT VIEW (OUTLET)

Table2: Vertical unit dimensions

Model

Range

A B C

With filters

No

filter

Controls assembly

Optional filter

Burner assembly

Fresh air inlet

LH SIDE VIEW (ACCESS)

DIM A

NON-ACCESS

ACCESS

PLAN VIEW

DF18/25 2350 2600 4972 4312

Vertical units are denoted the letter 'V' inserted after the model No. such as: DF5VAV150V.

12

4. Technical Data cont.

Diagram 4: DP units (VAV model shown) See diagrams 6 and 7 for burner details

Burner assembly

Air outlet

Fresh air inlet

Table3: DP unit dimensions

Model

Range

A B C

PLAN VIEW

Control cubicle assembly

DIM C

DF18/25 2350 2600 1060

DIM B

SIDE VIEW (ACCESS) REAR VIEW (INLET)

These units are supplied without a fan as a duct package denoted by DP inserted after the range

No. such as: DF5DPVAV150.

Refer to section 5 (Installation Details) for descriptions of burner types.

Note: See section 6 (Commissioning and Testing) for combustion settings.

13

4. Technical Data cont.

Diagram 5: AH units (VAV model shown) See diagrams 6 and 7 for burner details

Table3: AH units dimensions

Model

Range

Overall dimensions

Cabinet depth

Client case width

Client case length

Burner inlet gap

Burner outlet gap

A B C D E F G H

DF1

DF2/3

DF2/3/4

DF4

640 500 765

640 500 765

640 500 765

840 575 900

350

350

350

350

925 1600 200 1000

925 1600 200 1000

925 1600

1045 1600

200

200

1000

1000

DF3/4/5

DF4/5/7

DF5/7/9/11

DF7/11

DF9/14

DF9/11

DF14/18

DF11/14

DF14/25

DF14/18/25

DF18/25

840 575 900 350

1000 790 1000 350

1000 960 1000 350

1000 1110 1000 350

1000 1255 1000 350

1200 1420 1000 350

1200 1210 1000 350

1200 1360 1000 350

1200 1510 1000 350

1200 1650 1000 350

1200 1810 1000 350

1045 1600

1320 1800

1560 1800

1710 1800

200

200

200

200

1000

1200

1200

1200

1865 1800 200 1200

2020 1800 200 1200

1810 1800 200 1200

1960 1800

2110 1800

200

200

1200

1200

2250 1800

2410 1800

200 1200

200 1200

Air outlet

DIM H

PLAN VIEW

G

DIM C

DIM B DIM D

DIM E

SIDE VIEW

FRONT VIEW

These units are supplied without a fan and including a frame for fitting inside customers AHU denoted by AH inserted after the range No. such as: DF5AH150.

Refer to section 5 (Installation Details) for descriptions of burner types.

Note: See section 6 (Commissioning and Testing) for combustion settings.

14

4. Technical Data cont.

Process diagram: DF MUA heater.

Gas valve

Assembly

V3

P1 P2 P3

V4

P4

M1

V1 Internal strainer

V7

P6

V5 V6

FR

P7

P5

IT

T1 T2 T4

AF

V8 V9 V10 V11 V12

PS

P8 P9

Valve and instrument list.

V1 Main gas isolating valve AF Air fan

V3/V4

Combination main safety shut off valves

FR Flame rod with integral governor

V5 Motorised ball valve IT Ignition transformer

V6 Burner isolating valve

V7 Pilot gas isolating valve

M1

P4

Modulating control valve motor

Air pressure switch

V8 Pilot governor

V9/V10 Pilot solenoid valves

V11 Pilot isolating valve

V12 3 way solenoid valve (optional)

T1 Room sensor

T2 Duct sensor

T3

Outside air sensor (optional, see wiring diagram))

T4 Overheat device

P1 to P9 Pressure test points

15

4. Technical Data cont.

Process diagram: DF VAV heater

Valve and instrument list.

V1 Main gas isolating valve AF Air fan

V3/V4

Combination main safety shut off valves with integral governor

FR Flame rod

V5 Motorised ball valve IT Ignition transformer

V6

V7

Burner isolating valve

Pilot gas isolating valve

V8 Pilot governor

V9/V10 Pilot solenoid valves

V11 Pilot isolating valve

V12 3 way solenoid valve (optional)

M1 Modulating control valve motor

P4 Air pressure switch

T1 Room sensor

T2 Duct sensor

T3

Outside air sensor (optional, see wiring diagram)

T4 Overheat device

P1 toP10 Pressure test points

16

4. Technical Data cont.

Burner types

Diagram 6: NG1 VAV burner

Diagram 7: NG2 standard burner

17

4. Technical Data cont.

Diagram 7: Typical MUA burner controls

OVERHEAT

THERMOSTAT

BURNER

ON

2 3 4 7 5

SATRONIC FLAME PROGRAMER

6

JUMPER BELOW

150 kW

P

SV3

AIR

PRESSURE

SWITCH

SV1 SV2

SSOV

1

SSOV

2

8 B 9 A

FLAME

PROBE

IGN

TRANSF

3 WAY

SOLENOID

VALVE

PILOT SOLENOID

VALVES

(NOT USED

BELOW

150 KW)

MAIN

SAFETY

SHUT

OFF

VALVES

RELEASE

TO

MODULATOR

RELAY

LOCKOUT

RELAY

TYPICAL MUA BURNER CONTROLS

Diagram 8: Typical VAV burner controls

LOCKOUT

RESET

COOL/HEAT

RELAY

OVERHEAT

RELAY

4

LOCKOUT

RESET

7 2

A

3

SATRONIC FLAME PROGRAMER

5 6

JUMPER

BELOW 150 KW

COOL/HEAT

RELAY

P

P

FAN

ENABLE

RELAY

BRN

FAN

MAIN AIR

PRESSURE

SWITCH

BRN AIR

PRESSURE

SWITCH

FLAME

PROBE

IGN PILOT

SOLENOID

VALVES

(NOT USED BELOW

150 KW)

MAIN SAFETY

SHUT OFF

VALVES

TYPICAL VAV BURNER CONTROLS

Note: For further information regarding wire numbers, BMS controls etc., please refer to the main control panel wiring diagram supplied with the heater. A copy of this diagram is available by contacting Reznor Europe by quoting the serial number of your heater.

BURNER

ON

RELAY

8 B 9

LOCKOUT

RELAY

BURNER

ENABLE

OVERHEAT

THERMOSTAT

OVERHEAT

RELAY

18

5. Installation Details.

Installation

MUA and VAV heaters

Note: Only a suitably qualified, competent person should install this heater. sized as per the flanged inlet to the distribution head. For heaters with the extended internal ductwork, the ductwork should be sized to ensure that the external static resistance does distribution conditions, nature of gas and badge. adjustment of the appliance are compatible.

It will be necessary for the installer to refer to the appliance data plate for information specific to the air flow rates and gas rates for the particular appliance being installed.

Vertical outdoor configuration

The heater should be positioned onto a flat level prepared concrete base, with a minimum size to suit the footprint of the heater, and allow a minimum 500mm clearance from the building to the front face of the heater, 1000mm clearance to the access side, which can be

The heater should be positioned onto a prepared flat level concrete base, or support steelwork frame to give a minimum 500mm clearance to the bottom edge of the air inlet of the heater from floor level, 500mm clearance on the non-access side, and1000mm clearance on the access side.

Depending on the case size, heaters can be supplied in a single section or multiple sections.

The heaters should be fitted into position using a suitably sized fork lift truck through the lifting channels incorporated within the base frame, or determined prior to manufacture, 500mm to the non access side, and rear of the heater, and

500mm above the heater. (See diagram 1 in the technical data section).

Depending on the case size, heaters can be supplied in a single section or multiple sections, namely the support stand, burner section and fan section, with rubber sealing strips pre-fitted to the mating faces. The support stand should the lifting channels. To protect damage to the top of the heater casing, spreader bars must be used between the straps.

Ductwork criteria is identical to that stated for vertical outdoor configuration.

An air inlet weather cowl can be supplied as an optional item.

Note: careful consideration must be given to the location of the fresh air inlets in relationship to removable bird mesh screen panel is situation on the access side of the heater, using a suitably sized fork lift truck through the channel lifting points incorporated in the base frame, or via a crane with the lifting straps threaded through the channel lifting points, and spreader bars between the straps at the top of the frame at elevated levels. In site conditions where this is not possible the heater should be provided with specially designed inlet hoods to prevent the ingress of rain or snow.

Vertical indoor configuration

The heater should be positioned onto a prepared flat level concrete base, or support to prevent the straps from exerting any undue force onto the frame. The frame should be clamped to the concrete base on four corners.

The burner section should be lifted onto the steelwork frame with a minimum 500mm clearance on the non-access sides, and

1000mm on the access sides (See diagram 1).

Depending on the case size, heaters can be support stand, using a suitably sized fork lift ensuring that the control panel doors are supplied in a single section or multiple sections, truck, or crane, as previously described, namely the burner/base unit, and the fan section, with rubber sealing strips pre-fitted to situated on the access side. the mating faces. The burner/base unit should

The fan section should be lifted onto the burner section, using a fork lift truck or crane as previously described for positioning the base frame, ensuring that the fan access door is be lifted into position using a suitably sized fork lift truck or crane as previously described, with the fresh air inlet opening facing the outside wall. The fan section should be lifted onto the positioned on the heater access side, and the discharge spigot if side discharge is facing the building, and if top discharge the air off-take spigot should be furthest from the building. The burner section, with the fan discharge on side discharge units, on the opposite side to the fresh air inlet. The fan and burner sections should be bolted together using the fixings fan and burner sections should be bolted together using the fixings provided.

Four cover plates are provided to blank off the forklift truck lifting points in each section using provided. Four cover plates are provided to blank off the forklift truck lifting points in each section using the M6 setscrews provided on completion of the installation. the M6 setscrews provided on completion of the installation.

The supply ductwork into the building should be

19

The heater fresh air inlet is sized at 6m/s, the inlet ductwork should be increased to give

2.5m/s when using inlet weather louvres, cowls etc, to prevent water carryover into the heater.

The discharge ductwork should be sized as per

5. Installation Details cont.

the flanged connection on the distribution head.

Any external ductwork should be sized to ensure that the static resistance does not exceed the figure stated on the data badge.

Horizontal indoor configuration

Depending on the case size, heaters can be supplied in a single section or multiple sections. the local supplier of gas or the local contractor.

Any existing meter used should be checked, preferably by the local gas supplier, to ensure that the meter is adequate to deal with the rate of gas required by the heater.

Installation pipes

Installation pipes should be installed and tested in accordance with the current IGEM technical

It is usual for horizontal units to be mounted above floor level, due to the amount of floor space they would take up, and are normally positioned onto the roofs of internal offices/ standards.

Note: If a long pipe run is needed to supply the heater, the line pressure drop should be calculated before installation and the supply mezzanine areas or into the building steelwork. pipework sized accordingly.

For heaters being installed onto the roof of Gas pressure at the heater inlet under full fire offices etc., the roof must be adequate to take the weight of the heater, and be adjacent to an conditions should be at least 17.0mbar. Gas pressure with main burner off must not exceed outside wall, to allow fresh air to be ducted to the heater. A 1000mm clearance would be

100mbar. required on the access side of the heater, and a minimum 500mm clearance required on the

Boosted supplies

Where it is necessary to employ a gas pressure non-access side and top of the heater. booster, the controls must include a low

For heaters mounted in the roof steel work, a pressure cut-off switch fitted upstream of the steel support frame will be required incorporating a 1000mm access platform. event of reduced pressure and prevent

The fresh air to the heater should be ducted through the roof, with a fresh air inlet sized to achieve inlet velocities of 2.5m/sec. Supply ductwork should be sized to suit the flange automatic restart on pressure restoration. The cut-off pressure shall be decided by the local gas supplier.

The local gas supplier must be consulted connection on the distribution head, or for before a gas pressure booster is fitted. extended ductwork runs, sized to ensure that the external static resistance does not exceed

Guidance is given for low pressure cut-off switches in the current IGEM technical that stated on the data badge. standards.

The fan/burner section should be lifted into Where additional controls are used they should position with suitably sized fork lift truck, using be CE approved items. the lifting channels incorporated within the base frame, or via a crane with lifting straps threaded Electrical supply/controls through the lifting channels, with spreader bars Wiring external to the heater must be installed in positioned between the straps to prevent accordance with the current edition of the IEE damage to the roof of the heater. Wiring Regulations, and any other local regulations in force.

Connection of services Reznor Europe DF units operate from either a

Gas supply

The Reznor Europe MUA and VAV heaters are designed for use with natural gas (G20 & G25) and propane (G31).

415v TPN + E, or 230v 1PN + E 50Hz supply,

(refer to wiring diagram).

The method of connection to the main electricity supply must facilitate complete electrical

The gas type for this heater is marked on the appliance data badge. Check that the available gas supply is as marked and within the pressure range given in heater specification.

Service pipes

The local supplier of gas should be consulted at the installation planning stage in order to establish the availability of an adequate supply isolation of the heater. The method of connection should be provided adjacent to each heater in a readily accessible position.

Fig.1

Duct width of gas. An existing service pipe must not be used without prior consultation with the local gas supplier.

Meters

A gas meter is connected to the service pipe by

20

5. Installation Details cont.

Sensors should be wired with a twisted pair screened cable, Belden Ref 8762 or equivalent.

Where a duct discharge sensor is not factory

Mains supply cables are to be sized to suit the electrical rating of the heater as indicated on the data badge/ wiring diagram. fitted it should be installed in the centre of the discharge ducting as shown in Fig .1.

Control cable size should not be less than

0.75mm

²

CSA (refer to wiring diagram).

then wired back to the controller which is fitted Note: The appliance and the ancillary controls either inside, or adjacent to, the main control must be correctly earthed.

panel. Please note that sensor type may vary Internal wiring from that shown in Fig.1

The amount of interconnecting wiring will depend on the control system being used, this will be indicated on the schematic wiring diagram supplied with the heater.

21

6. Commissioning & Testing.

Commissioning and testing

Reznor Europe DF Heaters should only be commissioned by a suitably qualified and competent person.

Ensure all MCB’s in control panel are in the

OFF position.

Set motor overload to the motor plate FLC.

The Reznor Europe commissioning service does not cover responsibility for the connection of the gas and electrical services which remain the responsibility of the installer.

Set discharge head vertical distribution blades to give maximum spread, and the horizontal blades slightly upwards, to prevent downward air movement.

Discharge heads fitted with Novo-Jet nozzles

Commissioning sheets are available on request from Reznor Europe.

When heaters are used in conjunction with

Smartcom control, ensure that the engineers should be twisted to give maximum spread with no downward air movement.

Switch on electrical supply to heater. Check settings in the Smartcom are set to suit the application and appropriate sensor. These settings are fully detailed in the Smartcom manual. voltage across each Phase for 415 volts, and down to neutral for 240 Volts.

Switch on the 240 and 24 volt control circuit breakers power on lamp will energise.

General installation

The installation should be checked to ensure that work carried out is in accordance with the design requirements.

Check that there is an adequate air supply.

Check the BMS out station for the heater address reference number.

Override the system and burner enable relays to off.

Switch fan motor circuit breakers to ON

Gas installation

The whole of the gas installation, including the meter, should be inspected and tested for soundness and purged in accordance with the position.

Override system enable to ON position, air fan will start.

Check fan rotation is correct, if not, isolate electrical supply and change over two of the recommendations of the current IGEM technical standards.

Electrical installation

Checks to ensure electrical safety should be phases. Switch on electrical supply and re-check rotation.

Measure and record motor FLC on each phase.

Check and record air velocity over the profile carried out by a suitably qualified and competent person.

On MUA versions an adjustable profile plate is

Commissioning procedure incorporated and set at the optimum position

To be read in conjunction with the schematic and is marked by three centre punch marks in wiring diagram, and process diagram. line with the corner of each profile plate. The

Commissioning of Reznor Europe heaters optimum pressure differential is 1.25 mbar should be carried out by competent engineers, between pressure tapping points P8 and P9. with knowledge of the BMS control sequences.

Should the profile plate require adjustment,

Training courses are available at Reznor isolate heater electrical and gas supplies,

Europe. access inside the unit, open or close plates,

All heaters require the following inspection to be re-mark position and record opening size. carried out PRIOR TO commissioning.

Restart heater and check pressure between

All manual gas valves are closed. tapping points P8 and P9, air velocity and gas

All electrical supplies are isolated. line suction at tapping points P5.

Electrical earth continuity between the heaters,

Check within the factory area that no air gas pipework and main electrical supply. movement can be felt at low level. Adjust

Gas installation pipework has been tested for horizontal blades in distribution head or soundness.

Novo-Jet nozzles if necessary.

Gas installation has been purged.

On VAV heaters, measure and record motor

Note and record fan motor data badge details. current at high speed, measure and record

Note and record fan and motor pulley sizes, belt suction at pressure point P5. Reduce to reference and pulley centres, fan belt tension minimum speed, measure and record motor and alignment. current, measure and record suction at

Check overheat controller setting is 85°C. pressure point P5.

Commissioning settings are to be recorded on a

Check gas soundness of the gas control train commissioning sheet, available from Reznor by leak testing.

Europe on request.

Burner commissioning

Pre-firing commissioning

To be read in conjunction with the schematic

A laptop incorporating the control strategy, display device, or

Reznor approved wiring diagram and the process diagram.

Commissioning settings should be recorded on controller is to be connected to the heater. separate commissioning sheets, available from

22

6. Commissioning & Testing cont.

Reznor Europe on request.

Override system to ON (fan running). lockout.

If no pilot is fitted then the pilot gas rate will

Override the burner to ON, flame programmer need setting. Insert an allen key in the brass will commence a purge, followed by ignition cap screw and turn anti-clockwise ½ turn as sequence and lockout.

Open main gas isolating valve V1, and pilot isolating valves V7 and V11. Ensure burner isolating valve V6 is closed. shown in Fig. 2. Adjust start gas rate (Ps on valve) as shown in Fig.3. Set to 33% of the maximum gas rate (up to 146kW only) to obtain

Connect a suitable manometer to pressure tapping point P7.

2 mbar pressure at test point P5.

On units with a separate pilot line fitted check pilot gas pressure at test point P7 and reset governor as shown in Fig.4, if necessary, to

5mbar.

Additional lockout resets may be required to

Fig.5

Depress the lockout-reset button on the front of the Satronic flame programmer, a purge will commence, followed by pilot ignition and adjust pilot governor pressure due to the time allowed prior to lockout occurring.

Open burner gas isolating valve V6 and reset the lockout condition. A purge will commence followed by pilot ignition and main flame ignition at low fire.

Override the gas control valve motor to open

(see Fig.5) to hold the burner at high fire.

As the gas valve drives towards high fire the flame colour should be blue, with a maximum flame length of 250 - 300mm extending from the burner plates. If flame lengths in excess of

250-300 occur, or orange in colour, close burner isolating valve V6, until the correct length/colour is obtained.

Connect a manometer to pressure tapping point

P1. Measure and record the main gas inlet pressure, which should be in the range of 17.0 -

100mbar (refer to data badge).

Connect a separate manometer across pressure tapping points P5 and P9 to obtain the differential gas pressure.

For burner differential gas pressures refer to section 3 technical data for required gas and burner types, i.e. natural gas (G20), NG2 standard burner.

Connect a manometer to pressure tapping point

P3 and measure governor outlet pressure, which should be approximately 7.5 mbar (NG2

STD burner) or 13.0 mbar (NG1 VAV burner). If valve V6 had to be closed reduce governor

23

6. Commissioning & Testing cont.

to obtain this temperature rise if the main gas governor outlet pressure was increased to obtain high fire setting.

To adjust the low fire setting, slacken the M6 nuts from the motor ‘U’ clamp around the valve spindle (see Fig.11), and with a pair of grips on the valve spindle, minutely close the valve in small stages, until the 5°C temperature rise is obtained. Carefully tighten the ‘U’ clamp on to the valve spindle shaft, ensuring the shaft does not move.

Irrespective of low fire temperature rise, ensure that a good flame is present.

Override the gas valve motor to open and then back to closed to ensure the low fire setting has not altered.

The high fire stop has been factory set to ensure the valve opens fully, and should not require adjusting. outlet pressure and fully open valve V6. To ensure that the burner ignites smoothly and

To increase or decrease the gas supply consistently at low fire. pressure to the burner, turn adjuster clockwise to increase the governor outlet pressure, and

Repeat this 4-5 times to ensure trouble free ignition. anti-clockwise to reduce outlet pressure.

(See Figs. 6 to 10 for valve variations). It is strongly recommended that a pressure gauge is connected to pressure point P3 when adjusting governor outlet pressure.

Note: DO NOT adjust governor pressure when setting low fire gas pressure.

If increasing the governor outlet gas pressure

MUA only

With burner firing a minimum rate connect both ends of a manometer to the tapping points on the pressure switch sensing tubes, to measure and record the differential air pressure across the profile plate at full fresh air. Reading should be between 1.25-1.5mbar.

Adjust air pressure switch, screwing clockwise, does not increase the burner pressure at high increases the pressure range, anti-clockwise fire, then the gas control valve requires reduces the pressure range. (See Fig.12) resetting.

As a cross check at high fire, measure the outside air temperature and subtract this from

Fig.12 the duct discharge temperature, this should be

The ideal setting is normally 0.75mbar. Setting higher than 0.75mbar may give rise to nuisance

42º C .

Override the gas control valve motor to closed lockouts.

Ensure gas valve motor rotational switch is set to normal position. to drive the burner to low fire.

The flame at low fire should be a small VAV only continuous blue flame, along the full length of the burner, with a temperature rise of 5°C maximum over the outside air temperature. The

There are no profile plates on these units. The blown burner requires the system to have two air pressure switches to confirm both the low fire valve setting may have to be adjusted combustion and main airflows respectively.

24

6. Commissioning & Testing cont.

Check airflow of the combustion air fan.

Pressure in the burner chamber should be

1.25mbar. The pressure differential should be measured across the two test point fittings labelled P8 and P9 on the process diagram

Remove air sensing tube from air pressure switch, heater will lockout on air failure.

Replace and reset.

Adjust overheat thermostat set point down until

(see Fig.13), and located in the controls panel.

The pressure can be adjusted by first 85°C and reset thermostat by depressing red slackening the locknut with a 17mm spanner, heater goes to lockout. Reset temperature to pushbutton on front of unit (See Fig.15) then closing or opening the sliding inlet to the combustion fan/s by screwing the adjuster rod

Place multimeter across flame flame rod disconnection tab located on control panel terminal rail. Set meter to read µA. Remove disconnection tab. Flame current should be

1.5µA. Replace disconnection tab.

Remove disconnection tab with heater running, heater should lockout in less than 1 second.

Component Limiting concentration

Carbon

Monoxide CO

Carbon

Dioxide CO

²

10 0.001

2500 0.25 in or out (See Fig.14).

Ensure slide is locked in position once pressure is correctly set. Ensure combustion air pressure switch is set to 0.75mbar. Minimum air volume for VAV is factory preset.

Ensure main pressure switch is set to 1.25 mbar. Check maximum airflow of unit using suitable air volume measuring device. If air volume varies to that specified on the data label it will be necessary to change the fan speed.

Consult the manufacturer for advice and guidance before making any changes.

Safety checks

Ensure the system enable relay and burner enable relay are both overridden on, and the burner is firing.

Close burner isolating valve V1, lockout will occur. Open valve and reset lockout condition.

Nitric

Oxide NO

Nitrogen

Dioxide NO

²

1 0.0001

Combustion DP, DP VAV, AH, AH VAV

The concentrations of oxides of carbon and nitrogen in the discharged air measured on the dry basis shall not exceed the figures shown in the chart below, the figures given as a rise in level, (i.e. discharge air concentration minus the inlet air).

The combustion levels are taken at the sample

Component

Carbon dioxide CO

²

5 0.0005

Limiting concentration

Carbon monoxide CO 90 ppm (+/- 40 ppm)

1.1% (+/- 0.2%)

25

6. Commissioning & Testing cont.

burner (250 mm centrally, see diagrams 8 and 9 and Fig.16) and should be measured using a standard combustion analyser. The combustion shall not exceed the figures shown in the chart on the previous page.

If the levels are higher than in the chart , check that the air flow rates (particularly the minimum air flow) are in accordance with the data shown in section 3.If not, adjust until the required emission levels are obtained.

Diagram 8: NG2 standard burner combustion sampling position

25

0m m

Sample point position

Diagram 9: NG1 VAV burner combustion sampling position

Burner centre line

250 mm

Sample point position

26

Burner centre line

6. Commissioning & Testing cont.

point in the discharge air directly in front of the

Leak testing the gas line

The procedure should be used in conjunction with the process and instrumentation drawing.

1. Ensure that gas and electricity supplies are turned off and close manual valves V1, V6, V7 and V11.

Testing the pipework up to and including the

Testing the start gas pipework

11. Connect pressure gauge to P2 and open V7 and V1 to pressurise the start gas line up to the first gas safety shut-off valve.

12. Close V1. Leave the system for 3 minutes and check the pressure gauge. If the pressure falls, open V1 and leak test the start gas upstream main safety shut-off valves: pipework and re-test.

2. Connect a suitable pressure gauge to 13. If no external leaks are evident the start gas pressure test point P2.

3.Open V1 to pressurise the governor assembly. safety shut-off valve is passing gas.

To check this, replace the sealing screw on the

4. Close V1. Leave the system for 3 minutes and check for a fall in pipework pressure. If the pressure falls, open V1, and test for leaks with leak detection fluid. Make good as necessary pressure test point P2 and connect the pressure gauge to test point P6 and leave for three minutes with V1 still open. A rise in pressure confirms the upstream pilot valve is and re-check.

Note: 3 minutes should be allowed for all soundness. pressure checks.

5. If external leaks are observed, the upstream main safety shut-off valve is passing gas.

To check this, remove the sealing screw on the pressure test point 2, and connect the pressure gauge to test point 4 and leave for 3 minutes with V1 still open. A rise in pressure will confirm that the main valve is passing gas.

Replace the valve and re-check for soundness.

Testing the downstream main safety SSOV

6. Close V1 and connect pressure test points P1 and P4 with a length of rubber tubing.

7. Open V1 to pressurise the assembly up to the passing gas. Replace valve and re-check for

Testing the downstream pilot SSOV

14. Close V1 and V11, connect pressure test points P1 and P7.

15. Open V1 to pressurise the assembly up to the isolating valve, V11.

16. Using a leak detection solution, check all joints downstream of the second safety shut off valve up to V11. If leaks are detected close V11 any remake leaking joints. Repeat 15 and 16 to re-check after re-assembly.

17. If no external leaks are observed, close V1 and connect rubber tube to pressure test point

P1 and P6 to pressurise the assembly between burner isolating valve, V6.

8. Using a leak detection fluid check all joints downstream of the second safety shut off valve up to V6. If leaks are detected, close V1 and the two safety shut off valves. Connect pressure gauge to pressure test point P7.

18. Open V1, and rise in pressure indicates the downstream safety shut off valve is passing gas. re-check after assembly.

9. If no external leaks are observed, close V1 and connect rubber tube to pressure test point

P1 and P3 to pressurise the assembly between the two safety shut off valves.

Connect pressure gauge to pressure test point

P4.

10. Open V1, any rise in pressure indicates the downstream safety shut off valve is passing gas.

Replace valve and re-check for soundness.

On completion of commissioning, all adjustable devices should be sealed with suitable tamper evident seal.

27

7.Servicing.

The servicing of these heaters must only be BELT TENSIONING carried out by a competent person.

Reznor Europe do not recommend servicing any

• Calculate the deflection distance in mm on a heaters designed for permanent outdoor

basis of 16mm per metre of centre distance. installation in wet conditions.

• Set the lower marker ring at the deflection

It is recommended that the heater is serviced

distance required in mm on the lower scale.

• Set the upper marker ring against the bottom twice a year, a major service should be carried out prior to heating season, and a minor service

edge of the tube. after 2000 running hours.

• Place the belt tension indicator on top of the

After servicing the heater should be re-commissioned. force at right angles to the belt deflecting it to the point where the lower marker ring is level

Routine servicing with the top of the adjacent belt.

Note: Isolate electricity supply and gas supply

• Read off the force value indicated by the top before servicing.

edge of the marker ring.

Access to the fan, motor, drive belts and burner

• Compare this force to the kgf value in the is through the access doors on the side of the table overleaf. heater.

• If a belt tension indicator is not available, a

Remove and clean spark igniter with a wire

spring balance and rule will suffice. brush. Replace it every two years.

Inspect and clean the flame rod with a dry clean

Important cloth to ensure freedom from dirt and moisture.

Replace the flame rod when showing signs of

After the drive has been running for excessive wear. approximately 30 minutes, the tension should be

Remove protection boot from the spark electrode cap, with a clean cloth wipe clean both necessary. the HT and flame probe leads.

See table overleaf.

Check fan belts for wear and tension after 2000 hours of operation.

The tension of each belt should be determined using a belt tensioner.

Check condition of burner ports, if necessary, clear the ports using either a 1.8mm long series drill (NG2 standard burner) or 2.0mm long series drill (NG1 VAV box burner)

Note: Check stainless steel mixing plates for cracking.

Inspect the entire external system for signs of leakage, wear or general damage.

Check fan bearing for grease nipples, only the smaller range of heaters are fitted with “sealed for life” bearing, if fitted with nipples, re-grease using Shell Alvania R3 grease or similar.

Leak test the pipework and safety shut-off system in accordance with the procedure, and check gas soundness.

28

7.Servicing cont.

8.Troubleshooting.

General

Should either the burner fail in operation, or its light up sequence fail, the following procedures should be carried out.

Check that the connectors to the spark electrode and flame detector are securely fixed, and that there has been no interruption to the gas, air or electricity supplies.

Flame failure lockout is indicated on the heater via a red indication lamp. Reset can be achieved by:

a. Depressing the Satronic flame programmer

RESET button, situated within the heater control panel.

b. Depressing the reset button on the front of the electrical control cabinet.

If the burner still fails to ignite, proceed to carry out systematic checks in accordance with the fault finding guide.

Control system fault finding

The individual phases of the programming sequence on the Satronic DMG970 (see Fig17 overleaf). Are displayed in the form of flash codes. The following messages can be distinguished (see diagram opposite):

29

Message

Waiting for air proving switch

Pre-purge tv1

Pre-ignition tvz

Flash - code

| | .

| | | .

| | | | .

Safety time ts

Delay 2nd stage tv2

█

█

| .

| | .

Running | _

Low mains voltage | █ █ _

Internal fuse defect

>control box defect

| █ _

Description

| = short pulse

█ = long pulse

. = short pause

_ = long pause

8.Troubleshooting cont..

Error message

Lock out safety time

Stray light

Error diagnosis

Flash - code

| █ █ █ █

Possible fault

Within lockout safety time no flame established

| | █ █ █

Stray light during monitored phase.

Detector may be faulty

LED

Air proving switch in closed position

█ █ | | | Air proving switch contact welded

Air proving switch time-out

| | | █ █

Air proving switch does not close within specified time

Air proving switch opened

| | | | █

Air proving switch opens during start or operation

Loss of flame █ █ █ █ | Loss of flame during operation

Flash code for manual lockout

Manual / external lockout

| | █ █ █ █ █ █ █ █

Fig.17

Lock out diagnostics:

In the event of a failure the LED is permanently illuminated.

E v e r y 1 0 s e c o n d s t h e illumination is interrupted by a flash code which indicates the cause of the failure, therefore the following sequence is performed, which is repeated until the unit is reset. (See sequence bar diagram below)

Sequence diagram:

Illuminated phase Dark phase Flash code

| █ █ █ █

For 0.6 sec. For 1.2 sec. For 10 sec.

General troubleshooting

Symptoms Possible causes Remedy

Dark phase

No power supply.

Fuse blown.

Turn on main isolator, re-check.

Find fault. Replace fuse.

Heater will not start.

Programmer cycles continuously

Programmer locks out

Programmer locks out

(when flame is on).

Fan on overload.

Heater locked out.

Find fault. Reset overload.

Reset lockout.

Overheat thermostat activated. Manually reset and check setting is 85°C.

Micro-processor not programmed. Set up programmer.

Air pressure switch not acting.

Possibly stuck.

Reset pressure, or replace faulty switch

No gas.

No spark.

Insufficient airflow.

Turn on gas. Check pilot solenoid is opening.

Check spark lead and gap.

Check for: belts slipping, duct blocked, filter blocked.

Flame not seen by flame probe. Check probe lead, cap, replace faulty flame probe.

Check programmer. Replace programmer.

Flame signal not accepted by programmer.

Unstable main flame.

Lack of gas.

Check fan belts for slipping.

Check gas supply.

Note: In the event that the fault cannot be traced, it is recommended that the services of a Reznor Europe engineer be obtained.

30

9. Removal & Replacement Of Parts.

Note: Replacement of components should only be carried out by a competent person.

Isolate electrical and gas supplies before replacement of any parts.

Please consult Reznor Europe for advice before replacing any parts other than those listed in the recommended spares list.

Check for gas soundness after replacing gas and tighten unions. Gas train should be leak tested and re-commissioned.

Drive belts

Access is via the access doors in the fan carrying components. Access for replacement of the main burner assembly, ignition electrode, flame electrode, fan, motor, drive belts, is via section. Loosen motor adjusting screw, remove belts. Replace belts and re-tension. the access doors in the fan section.

Inadvertent substitution or replacement of

Fan drive motor

Disconnect cable to motor. Loosen motor slide similar components, particularly those with plug-in bases, could be hazardous. plate by adjusting screw, then remove belts.

Remove motor pulley and bush. Unbolt motor

Main burner assembly

Disconnect main gas supply union and pilot gas supply, HT cable and flame rod connections.

Unbolt burner straps from the burner supports from slide plate, re-fit motor, pulley and bush.

Check both motor pulley and fan pulley are parallel and in alignment. Re-fit belts and re-tension. and remove assembly from heater. If necessary, replace any damaged sections as Isolate electrical supply, remove cover from required, re-join flanges using special burner sensor, unscrew cable terminals, remove cable, gasket. remove fixing screw and withdraw.

Replace burner assembly in reverse order to Refit new duct sensor in reverse order. removal. Check operation and combustion as detailed in the commissioning instructions.

Ignition electrode

Isolate electrical supply, remove HT cable,

Room sensor

Unclip room sensor, unscrew cable terminals, and remove cables. Refit new room sensor in reverse order. unscrew ignition electrode from burner body, replace with new and reconnect HT cable, and protective boot.

Air differential pressure switch

Remove cover of pressure switch, terminal box.

Disconnect cables, remove sensing tubes and

Ignition transformer

Isolate electricity supply, disconnect HT lead.

Disconnect cable from terminal block. Unbolt ignition transformer and remove. Refit new transformer, reconnect cables and HT lead then test. unbolt pressure switch from mounting bracket, replace the switch, re-connect the sensing tubes, re-connect the cables.

Re-commission the differential pressure switch by setting to 0.5 mbar and check operation. It will send the heater to lockout if adjusted any higher than the air pressure differential.

Flame electrode

Isolate electrical supply, remove cable from flame electrode, unscrew old rod and replace with a new one, bending the probe through 45° so that the probe runs parallel to the burner plates. It will be necessary to straighten the old probe prior to unscrewing from the burner.

Modulating gas valve control unit

Isolate electric supply, unbolt motor clamp from

Control panel components

Burner programmer

Unscrew body from plug-in terminal base and replace.

Indicators

Unscrew lamp cover, remove bulb, and replace with new. valve spindle and remove motor from motor mounting bracket, replace and re-connect. Care should be taken not to move the valve spindle,

Relays

Unplug relay body and replace with new. as this will alter the low fire setting, requiring the heater to be re-commissioned.

Gas train components

Isolate gas and electricity supply; disconnect

Motor MPCB (protective circuit breaker)

Disconnect outgoing motor cables, loosen overload to contactor connecting screws, and replace overload unit, reconnect cables. electrical connections to valves and modulating valve motor unit. Unscrew unions on gas train, replace components where necessary, reseal using approved thread sealing compound, re-fit

31

9. Removal & Replacement Of Parts cont.

Control MCB

Loosen cable terminal screws and remove the

Remove all wires from the outstation, noting their positions, and unscrew from base plate. incoming and outgoing cables. Unclip the MCB Refit new controller and rewire, ensure all from the Din rail. Replace MCB, re-connect connections are in the correct positions. cables.

Overheat device

Isolate electrical supply, remove cables, then remove fixing screw. Remove clip from end of phial inside heater then withdraw phial and

The controller will require re-addressing, and the controller software downloading. This should be carried out by a Reznor Europe engineer or agent. capillary tube through hole in cabinet and, where applicable through hole in conduit box. Replace with a new unit, set to 85°C, and test as described in the commissioning section.

BMS outstation (if applicable)

10. Spare Parts.

The following table shows a list of recommended spares.

Item Description Part No. Item

Spark electrode N1014

Flame probe M18x150 N1007

Flame probe ¼¨

NPTx190

N1024

HT plug cap N1008

HT lead

Satronic DMG 970

Vee belts

Ignition transformer

N1012

N1023

See technical specification

N1010

Description

¼¨ BSP solenoid valve

Part No.

N3041

⅛¨ BSP solenoid valve N3055

Modulating control motor

NM24A SR

Modulating control motor

NM230A SR

Overheat device

Alternative air pressure switch

JD2

Air pressure switch

Krom Schroder

N9002

N9028

N7044

N3038

N3069

Duct sensor/ thermocouple

See wiring diagram

BMS outstation

(if applicable)

Stainless steel burner mixing plate

Angled stainless steelburner mixing plate

(T or H sections only)

See wiring diagram

N0006

N0007

32

11. User & Operating Instructions.

1. Introduction

The Reznor Europe Direct Fired (DF) heater is a fully automatic, highly efficient source of heat.

It is of solid construction with a high finish, and properly cared for will give you as many years of

4. Care of your heater

Keep the area around the heater free from rubbish or debris.

Ensure that there is an unrestricted flow of fresh air to the heater inlet. reliable service.

It will provide you with warm air in the winter,

Do not put anything on top of the heater or lean anything against it. and ventilation air in the summer, and at all times generate a clean, fresh atmosphere.

Your heater carries a 12 month warranty on all components.

Use a damp cloth and mild detergent, if necessary, to clean the external surfaces of the unit.

Your installer will have advised you of any adverse ambient conditions at the time of commissioned is fully automatic. No adjustments are necessary. changes in your premises do not result in any deterioration of the heater’s environment.

2. Lighting instructions Your heater should be regularly maintained.

During normal operation the electricity and gas supplies can be left turned on, and as such the 5. Servicing heater will light up under fully automatic control.

Use the display device,

5H]QRU approved controller, or BMS system where applicable to

We recommend that the heater be serviced by a competent engineer every 6 or 12 months, depending on usage. bring the heater on using the time clock Should your heater require any spare parts, you functions. will find that the components are readily available from the Reznor Europe spares

3. Shut down department.

For short periods

Use the display device,

5H]QRU approved controller, or BMS system where appropriate to

Reznor Europe offer a maintenance service.

Details are available on request.

See below for contact details. turn the heater off using the time clock functions . 6. Understand your heater

For long periods It is helpful for you to understand the automatic

Turn OFF the gas and switch OFF the electrical function of your heater. The automatic light up is supply to the heater. The display device or

Reznor approved controller will have a battery back-up of its program.

initiated by the control station, and then controlled and monitored by the Satronic programmer fitted in the control panel of the

Note: Using this procedure the frost protection heater. will not function.

33