Radiant Tube Heaters BTwin BTL25 French Model

Radiant Tube Heaters  BTwin   BTL25 French Model
Radiant Tube Heaters
TM
BTwin BTL25
French Model
II 2Er3+ Category
TECHNICAL INSTRUCTIONS FOR
INSTALLATION – MAINTENANCE & USER
Warning
Please read this document carefully before commencing the installation and leave it with the user after
installation. The document accompanying each unit is meant for the installer and the user. This document
contains instructions for installing the heater and flue system and describes in particular how to carry out gas
connection & electrical connection. Subcontractors must also receive this document.
12.10.327 /B
10/2012
-2-
INDEX
1
RULES
P4
2
TECHNICAL SPECIFICATIONS
P5
3
DIMENSIONS
P6
4
APPLIANCE ASSEMBLY
a/ Packaging
b/ Appliance assembly
c/ Burner, extractor and sleeves assembly
d/ Reflectors assembly
e/ Mounting of anti-rotation strap
P7
5
HANGING AND FIXING THE UNIT
P 10
6
CLEARANCES
a/ Distances to unprotected combustible materials
b/ Minimum recommended mounting height
P 12
7
EVACUATION OF COMBUSTION PRODUCTS
Type A
Type B
P 13
8
INSTALLATION METHOD & CONNECTIONS
a/ Electrical connection
b/ Flue system
c/ Gas connections
d/ Option ‘Failure signal transmission’
P 16
9
TEMPERATURE REGULATION
P 18
10 PROGRAMMING
P 18
11 SETTING UP
P 18
12 MAINTENANCE
P 19
13 GAS CHANGE
P 21
14 FAULTS – POSSIBLE CAUSES - SOLUTIONS
P 22
15 ELECTRICAL SCHEMA
P 23
16 OPTIONS ON REQUEST
P 24
17 PARTS LIST
P 24
18 LIST OF OFFICIAL TEXTs
P 25
-3-
1 Rules
GENERAL CAUTION
•
•
•
•
•
•
The installation will have to be in compliance with the norms in force and be carried out
according to traditional rules by a skilled worker..
The installer will have to refer to the various existing official documents according to the
different stages that the installation will require (see enclosure 1 at the end of this
document).
The radiant tubes are CE certified and approved for use in many countries. In order to
meet the national requirements only appropriate models should be used (in case of
doubt, please contact us). The guarantee of conformity to regulations and standards
does not apply to units designed for the French market but installed in foreign countries.
The hotpoint of the heater amounts to more than 150°C. Please follow the directives of
the competent authorities and respect the rules in force related to classified buildings or
risky sites.
The use is also prohibited in all the premises where there are corrosive fumes, even if
there are small quantities of them, whose combination with water vapour and/or
combustion products will entail abnormal deteriorations of the appliances. For example :
chlorinated, sulphurous, ammonia or sodium products and diverse acid products
All the requirements of the present regulation concerning ventilation and purifying shall
be respected.
GUARANTEE LIMITS
Warranty is void if following instructions are not respected:
• The heaters are only designed for use in non domestic applications with exclusion of any
other utilization.
• Heaters must be installed inside the room, protected against humidity and bad weather
conditions.
• Heaters must not be installed in atmospheres containing aggressive or corrosive
vapours, even in small concentrations as the combination with combustion products can
deteriorate the material (e.g. : chloride, sulphurous, ammonium, sodium and all kind of
acid products)
• Storage of heater must be done carefully avoiding shocks and ensuring that heater is
protected against bad weather conditions.
• The installation must be in accordance with these instructions
• Modification to this appliance is not authorized
-4-
2 Technical specifications
Model
Nominal heat input
Combustion efficiency
Radiation factor
NOX class
Electrical connexion
Fuse protection
Starting electrical power
Functioning electrical power
Combustion air & venting
Combustion air inlet opening type A & B
Flue outlet diaphragm diameter
Air pressure switch adjustment
Turbine discharge
Weight
kW HI
%
VA
VA
mm
mm
Pa
mm
kg
BTL25
21
85
0,57
4
230/240V 50Hz single phase
1 fusible 5A
115
80
A2, B22
Ø35
Ø48
64
Ø133
63
Adjustments in function of gaz
Distributed gas
Gas category for France II2Er3+
Gas reference
Heat input (Hi) of gas reference
1013mbar
Nom.
Inlet 10référence1013
pressure mbar mbar 15°C
Min. inlet pressure min mbar
Max. inlet pressure max mbar
BTL25
Ø injector mmx100
Pressure by injector mbar
Gas flow 15°c 1013mbar
2H, 2E
2L, 2E
3P
x
x
x
G20
G25
G31
34,02MJ/m3 29,25MJ/m3 46,34MJ/kg
20
25
37
17
20
25
25
30
45
390
11
2,22 m3/h
* RB = blocked regulator
-5-
390
16,5
2,58 m3/h
240
RB*
1,63 kg/h
3B
x
G30
45,65M/J/kg
29
20
35
240
RB*
1,66 kg/h
3 Dimensions
2
1
1
Combustion air inlet opening
2
Flue pipe outlet opening
-6-
4 Appliance assembly
a/ Packaging
Qty
1
1
1
3
Designation
Carton bloc brûleur / bloc extracteur
Tube Ø76,1 – lg : 4 400
Tube Ø76,1 – lg : 3 750
Réflecteur cycloïdal – lg : 2 824
Ref
1030001
1030212
1003474
b/ Appliance assembly
Plan for hanging points under the roof following figure page 6.
The total incline should be between 0 and 100mm maximum, Burner should be lower than the
Extractor.
The long tube (A) in mounted burner side (D), the short tube (B) extractor side (E). The
central sleeve (F) is used for the connexion of the 2 tubes.
B
C
A
E
F
D
Tubes are fixed on brakets (C) with fixing rings.
Attention to respect the position of the brakets (C).
The hanging holes have to be always in the direction of the extractor (E).
-7-
c/ Burner , sleeve and extractor assembly.
Make certain that the screw (A2) goes through the elongated hole (A1) ensuring so that the
moving elements will come to a standstill !!
d/ Reflectors assembly
Attention : Take off the plastic protection of the reflectors (H).
All the 3 reflectors are similar.
Put the fixing brackets of the reflectors (G) in open position.
Position the reflector (H) in the grooves of the traverse.
Put the fixation parts of the reflectors (G) in closed position and screw these parts in order to
maintain the reflectors.
H
G
H
H
-8-
e/ Mounting of anti-rotation strap
Installing anti-rotation strap of burner unit.
P
S
P
At burner unit side (P), attach the
anti-rotation strap (S) to the screw
surpassing the socket with the
supplied lock nut (T).
S
T
Crosswise (C), fix the anti-rotation
strap (S) with the supplied 2 screws
and nuts (U) applying the hereto
provided 2 holes.
S
C
U
P
S
C
-9-
Top view, installed unit
A
H
F
D
C
Burner side
Extractor side
B
F
E
5-Suspension/Fixing
Suspend the radiant tubes by means of chains or cables of adequate length fixed to
framework, under shores or portals, between pillars or against a wall. Optional fixing parts can
be supplied by GAZ INDUSTRIE.
HORIZONTAL HANGING
WALL HANGING
ATTENTION : For a good system efficiency, do not incline the unit up to 30°!!
Kit composition :
Model
BTL25
Horizontal hanging
Reference of the kit
0340132
- 10 -
Wall hanging
Reference of the kit
0340125
SAFETY INSTRUCTIONS
Care must be taken to install the anchor points perpendicular to the end supports.
The model BTL25 contains 4 points of anchorage
Wrong
Wrong
Good
Incline advice 0 à +100mm
Very important:
Make use of a flexible suspension system enabling the expansion of the emitter tubes but
avoiding extreme oscillations.
Wall supports, supplied on request by GAZ INDUSTRIE take this instruction into account.
Mark
A
Designation
Required anchor points
- 11 -
6 Clearances
a/ Minimum distances towards unprotected combustible materials
Combustible
materials
Units must be installed so that the minimum
clearances towards unprotected combustible
materials are maintained.
Furthermore, a thermal insulation is to be installed
between the hanging support of the appliance and
the material on which it is fixed, in case this material
should be of a flammable nature.
CAREFUL : Refer to the rules in force.
Combustible
materials
b/ Recommended minimum height
The minimal recommended mounting height in
relation to the ground and in the case of global
heating of a closed building if:
Device
BTL25
Horizontal
hanging
3,60 m
Wall hanging
3,00 m
Heights and mounting positions depend of the
building structure and of the study implantation.
PARTICULAR CASES :
1) During the installation of an appliance above an overhead crane, provide if necessary
the protection of the crab’s motor and of electrical equipments by the means of an
insulating sheet.
2) Avoid the installation of radiant tubes above bulky machines or stores which could
prevent the diffusion of radiation towards the workers or users.
3) In the presence of lifting ramps (vehicle repair workshops) care should be taken not to
fit the radiant tubes directly above these ramps. In fact, deterioration may occur to cars
with bodies or covers which could stay on the high position of the ramp.
4) In the case of a workshop including pits or hidden zones, we cannot guarantee in
these zones the same conditions of comfort as in the rest of premises.
- 12 -
7 Evacuation of combustion products
According to the type of building, to the insulation or to the air tightness of the building, there
are 3 possible solutions:
Type A - Throwing out of the combustion products into the atmosphere
Type B - Individual fluting of each unit outside the building.
Type B - Appliances connected to a flue manifold system.
The following indications about the air renewal concern the good functioning of the
appliances. Do not forget also to take into account the rules concerning people leaving in the
heated premises
TYPE B
TYPE A
Burner block
Extractor block
TYPE A
THROWING OUT OF THE COMBUSTION PRODUCTS INTO THE ATMOSPHERE
GAZ INDUSTRIE radiant tubes have a good combustion hygiene which has been controlled
for the CE mark. However, they can only be installed and used in well ventilated premises.
Radiant tubes can be installed without evacuation ducts for the combustion products within
the limits of the regulations in force. In that case, no modification has to be brought to the
units which are already equipped with a protection grille.
Attention : In public buildings, the evacuation of flue gases is obligatory.!!
* However we draw your attention to the fact that combustion products emitted into the
atmosphere can perceptibly modify the humidity level depending on the air change rate of the
building.
In case products of combustion are not evacuated outdoors, ensure that the location where
the unit is installed provides sufficient air to ensure a good functioning of the unit and the
dilution of the combustion products by 10 m3/h per kW installed.
Do not allow combustion products to come into contact with combustible materials.
CAREFUL : refer to the rules in force.
- 13 -
TYPE B
a / INDIVIDUAL FLUTING OF EACH UNIT OUTSIDE THE BUILDING
1
- Remove grill at exhaust pipe (1).
- And replace with connection piece Ø100 (2) for Ø97 tube.
- Do not use grill as protection for a flue pipe end.
- Air inlets must be sufficient in the premises in order to
allow a good supply of the burner with air of combustion
2
Plan for an external air flow of at least 1,75 m3/h per
installed kW.
SAFETY INSTRUCTIONS CONCERNING THE INDIVIDUAL EVACUATION DUCT :
- No reduction of diameter can be accepted after the connection piece.
- It must be made out of stainless steel or aluminium with smooth and rigid duct.
- The evacuation must be realized according to the norms in force in each concerned country.
- The maximum lenght of the exaust pipe do not be up than 8 meters + 3 bends 90° + 1
terminal ( see on the spreadsheet herunder).
- The duct must not include low point.
- Any accessory made out of plastic or PVC is absolutely prohibited.
Fumes
temperature
222 °C
Air flow
BTL25
3
52 m /h
Volumic flow
3
100 m/ h
Massic flow
68 kg/h
Flue system pipe lengths
Elbow 90°
Ebow 45°
Std protection cap against rain
1m rigid hose
2m
1m
2m
1m
CAREFUL : refer to the rules in force.
- 14 -
b / APPLIANCES CONNECTED TO A FLUE MANIFOLD SYSTEM
Very important :
The flow extracted on each appliance must be equivalent.
The installer will have to comply with the official texts of each country concerning mechanical
evacuation and will have to get information from the competent national organisations about :
1) how to balance the network.
2) the controls and the different securities to put into operation.
Schematic diagram
N°
1
2
3
4
5
Désignation
Collector
Slope 4mm/m
Security pressure switch
Extraction fan
Condensation collector
It is necessary to take off the grille of flue outlet from the appliances and to replace it by a
connection piece. Connect the top of the dilution piece to the collector with a flue tube and
check that the connection of this duct is made on the side of the main duct (collector) and not
from below. Place the dilution piece on the tube coming from the appliance and fix the 3 fixing
parts by the means of screws or rivets.
Do not take off the screwed rod which is used as a thrust.
BTL25
Extracted flow
dilution included
210 m3/h
Plan for that the air entry in the building is a minimum of
10m3/h per kW.
Details for the connection on collector
N°
1
2
3
4
Désignation
Connection piece BTwin
Evacuating pipe Ø97
3 fixing parts at 120°
Dilution piece (Option supplied by GAZ
INDUSTRIE. on request)
5 Pipe Ø125 mini of collector
6 (Diaphragm or equalizing plate) if
network has to be equalized
7 Collector (main duct) connected to a
general extraction fan
- 15 -
8 Installation and connections (Gas and electricity)
G0
a/
Electrical connection
Mark
Désignation
E1
Power cable (supplied with unit) L = 1.5m (3 x 0.75 mm2)
E2
Junction box
E3
Power supply unit
E4
Power box (accessory Gaz Industrie)
E5
Power supply 230V 50Hz phase neutral earth
E6
Space sensor (accessory Gaz Industrie)
In case of electrical installation without neutral (or neutral of bad quality), an insulation
transformer has to be foreseen in order to create an artificial neutral
CAREFUL : In no case should the electrical cable be located on stay on the reflector or
on the fonctional block of the appliance.
- 16 -
b/
F1
F2
Flue system
Flue outlet connection Ø100 (accessory Gaz Industrie)
Exhaust pipe Ø97 made of rigid material (not supplied)
c/
G0
G1
Gas connection
Gas connection of the unit - G ¾″ gas male
Flexible pipe (special model, NF approved for public buildings)
Ensure pipe is not liable to pressure load.
(possible to replaced with copper tube with min. Ø500mm)
Pressure relief valve(installed upstream of each unit conform the gas supply
pressure)
Gas filter
Cut-off valve ¼ turn per unit
Gas pipe
Main cut-off valve
G2
G3
G4
G5
G6
d/
Option " Failure signal transmission "
This option allows the transmission of the failure signal (on each individual unit or per group of
units) to a control panel or the GTC system.
To ensure safe working, the transmission of the failure signal happens by means of a dry
contact controlled by a relay incorporated inside the unit (3).
In order to avoid undesirable shutdown at each ignition attempt, it is recommended to delay
the failure signal of the control panel or GTC by 30 seconds.
The unit is delivered in standard version with a closed contact, if you want open one, you may
ask us at the order.
(1) Lockout relay plug
(2) Red light default
(3) Lockout relay
(4) Dry contact
4
NC
- 17 -
NO
9 Temperature regulation
It is advised to foresee an automatic regulation according to the heating needs.
It is necessary to foresee a regulation per room or per zone.
The regulation occurs completely by the electric power supply of the units.
We advise the use of a resultant regulation for the complete installation, regardless global
local or zonal heating. This regulation consists of an electronic regulator and a resultant
sensor registering the energy radiated by the unit(s) and controlling the installation on the dry
resultant temperature being a better comfort criterion than only the air temperature. The
regulator contains a lowering of the occupation temperature : therefore is it necessary to use
a dry contact from a clock or relay.
We advise to respect the instructions concerning the material and particularly :
- To position the sensor at about 1.5m from the ground between two appliances so that it
receives a homogeneous radiation,
- To insulate the sensor from the wall on which it can be found in order to avoid the cold
radiation of the wall through the interposition of an insulating material (glass wool, wood, etc.),
- The connection between sensor and regulator must be made out of armoured cable or
phone cable, 2 pairs.
- In any case, do not put these wires in the cable path which already contains many wires
carrying energy
Material supplied by GAZ INDUSTRIE :
- Regulator with sensor Infracapt 20.10.
- Energystat, model Energystat 10 (1 zone), Energystat 12 (2 zones).
- Standard regulation box or specific on demand.
10 Programming
The clock index shall be placed so as to activate the start up about 30 minutes before the
premises are occupied. The time lapse should be modified according to the inertia of the
building and to the external temperature.
In the case of a very low external temperature, it is advised not to stop the heating during
periods of inoccupation, but instead to simply reduce the temperature.
It is advised not to stop the heating during short interruptions in the use of premises.
11 Setting Up
- After resistance test for mechanical seals and cleaning of gas line:
- Clean the gas network.
- Check that electrical supply is correct.
- Check presence and correct state of the flue installation.
- 18 -
FUNCTIONNING CYCLE :
Appliances are regulated in factory and do not need any additional adjustment on site.
- As soon as the electrical supply is turned on, beginning of the pre-purge sequence of about
15 seconds (yellow and red control lamps light).
- Control of the negative pressure in the tube through differential pressure switch.
- When the negative pressure is sufficient, the ignition spark starts and the electromagnetic
gas valve opens.
(yellow lamp lights and red lamp turns on).
- When the sensor detects the flame, the ignition spark stops and the appliance functions as
long as it is supplied in gas and in electricity.
. If for whatever reason the flame is no longer detected, the electrovalve closes and the unit
goes to lockout.
(yellow and red control lights turn on), then the appliance attempts an other ignition and a
second working cycle starts.
- In the event of a second ignition attempts without success, the unit again goes to lockout.
The ignition sequence can only start again if the electric supply is cut and reconnected some
seconds later.
. While operating, only the yellow control light stays on.
- In case of technical problem, refer to paragraph 14 « Faults - possible causes ».
12 Maintenance
We recommend to check the appliance and the installation at least every year.
The checking must be made by skilled personnal. A maintenance contract is advised.
CAREFUL : refer to the rules in force.
CAREFUL : INSULATE GAS AND ELECTRICITY BEFORE ANY MAINTENANCE WORKS.
Check that access conditions and minimum distances are respected.
List of necessary tools :
Brush, duster, paint brush, flue brush, vacuum cleaner, small case of electromechanical tools.
- 19 -
MAINTENANCE INSTRUCTIONS :
1) Emitter tubes
Clean up the external tubes with a metallic brush – remove the burner block to inspect the
inner side.
In case of a considerable dust deposit the tubes should be cleaned inside. Use hereto a
bottlebrush with appropriate diameter or a dust aspirator.
2) Reflector :
Inspect inner side of reflector and if necessary clean with soft cloth and soap water. If
necessary use soft metal wax.
3) Extraction Turbine
Check that it turns freely and remove with a brush any accumulation of deposits that may exist
on blades. Also remove dust from the fan volute.
4) Motor and cooling fan of motor axis :
Remove dust with compressed air (careful with the turbine over speed) and clean the aeration
ears.
5) Ignition and security box :
Remove the electrical plate and remove dust if necessary.
Check that the control contact of negative pressure occurs correctly.
6) Gas tray set and mono-electrode
- Remove the electrode mounting panel. disconnect the electric wires, inspect the electrode
brush it and change it if necessary. Control the gap which must be 4 mm.
- Disconnect the electric wires of the electrovalve.
- Take out the gas tray set by taking out the assembly screws on the face.
- Clean the injector, the burner and the burner head which must not be sooted up.
- Clean the electrovalve and regulator filters and the cartridge filter.
7) Connection of pressure switch :
1
2
N° Désignation
1 Burner depression plug
(green pipe)
2 Pressure plug on the air inlet
8) Evacuation duct :
Check and clean the fume ducts according to the rules in force.
- 20 -
REPLACEMENT OF PARTS :
Mono-electrode :
Dismantle the electrode carrier by unscrewing fixation screws. Change the set if
necessary. The gap between the electrode and the earth electrode must be 4 mm.
Burner and injector :
Dismantle the electrode carrier. Unscrew the burner, unscrew the injector and change
them if necessary. When the injector is dismantle, the joint must be replaced.
Ignition and security box
To take it out, take off the 4 fixation clips retaining it to the frontage panel, disconnect
the connector and disconnect the HT ignition wire.
Pressure switch
Open the superior bonnet, disconnect and identify the cable terminals and take out the
pressure switch from it support.
Fan Motor Group
Loosen the 4 nuts to easily remove the fan motor group.. To unfix the turbines, loosen
the six-sided nut by means of an Allen key on the flat surface of the motor axe.
13 Gas change
- The gas conversion must be done by qualified technicians.
- When converting to another gas type, only the injector (5) must be changed.
- We refer to the table at page 5 showing the injector diameters to be respected.
- This table also indicates the inlet pressure and the pressure by injector that must be
respeced
Note : A conversion kit is available on demand (consult our price list for components). The kit
comprises : injector, seal and gas label (must be adhered on the old label).
Successive checks to be done
- Check inlet pressure of working unit by means of a manometer connected to the pressure
connection (2) (See also table at page 5).
- Check pressure at gas pressure connection (4).
- Adjust pressure at the injector by using the adjustment screw. (3) (See table on page 5).
- Fix appropriate gas label
Note : For the 3rd family gases 3+ PROPANE or BUTANE the regulator is blocked (3)
(completely screwed in).
Mark
1
2
3
4
5
6
Designation
Electrovalve inlet
Supply pressure intake (unblocked the screw in
order to measure the pressure)
Pressure regulator (remove the brass plug
terminal in order to access to the regulator screw)
Injector pressure intake (unblocked the screw in
order to measure the pressure)
Brass injector (carved in mmx100)
Electrovalve power supply
- 21 -
14 Faults – Possible causes - Solutions
Before any replacement of components internal to the appliances, be sure that :
1) the electrical supply of appliances is correct.
2) the gas is correctly supplied until the gas inlet of one or several appliances. (gas filter
cleaned).
FAULTS
POSSIBLE CAUSES
SOLUTIONS
the motor does not run
(red and yellow lamps light on)
Impeller jammed
Motor seized up or failed
burnt fuse
Clogged chimney
Faulty motor
Folded or disconnected pressure
switch pipes
Faulty ignition box
Dirty impeller
Cracked electrode
Too big gap for ignition electrode
Faulty control box
Faulty electro valve
Ignition and security box
Electrode out of position
Default of gas supply
Faulty flame control
Clean the fan casing
Unseize and/or change
change the fuse
Check - Clear
To be cleaned or changed
Replace them correctly
To be changed
To be cleaned (compressed
air)
To be changed
To be adjusted (4 mm ± 1 mm)
To be changed
To be changed
To be changed
To be repositioned
Clean filter and pipes
Check the ionisation sensor
and electrical connections
(or quality of neutral)
To be changed
Check regulatin.
To be adjusted
Change motor
Correct and verify
the motor turns
(red and yellow control
lamps light on)
but the appliance does not ignite
The pressure switch works
correctly but there are no sparks
Sparks occur but the burner
ignition does not occur.
(yellow lamp lights on, red lamp
lights off)
Ignition occurs but the appliance
stops afterwards
Abnormal noice.
Ignition problems
Inversion phase neutral
Faulty ignition box
Disordered burner.
Friction of turbines
Motor bearing defect
Coupling of emitter tubes
- 22 -
15 Electrical Schema
INTERNAL
N°
1
2
3
4
5
6
Designation
Alim + Fuse
Red lamp
Yellow lamp
Electro valve
Pressure Switch
Electronic control box
4
2
3
5
1
6
INTERNAL
With isolating transformer
N°
1
2
3
4
5
6
7
Designation
Alim + Fuse
Red lamp
Yellow lamp
Electro valve
Pressure Switch
Electronic control box
Isolating transformer
7
4
3
5
2
1
6
- 23 -
16 Options on request
Protection grille BTL25
Isolating transformer
Return of defect : Normally closed
0340144
0240017
0240016
17 Parts
5
BTL25
2
3
4
2 Gas regulator
Réf : 10 21 210
1 Plug socket male and female
Réf : 02 80 217
4 Electric control box
Réf : 80 21 101
1
mono electrode assy
Réf : 10 30 016
3 Yellow inspection window
3 Red inspection window
Réf : 10 25 243
Réf : 10 25 244
6 Fan Motor group
5 Pressostat BTL25
BTL25
Réf :06 12 053
- 24 -
Réf : 10 21 208-64
Organisations which have the power to interfere before, during and after the setting
up of appliances have to be consulted before the installation of the appliance in
order to be informed about the norms and rules in force.
18 List of official texts
(noo exhaustive)
- 25 -
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