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31 50 006

"Gas Fired Air Heaters


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INSTRUCTION MANUAL

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Mark II & Mark III Models


100 • 150 • 200
300 • 400 • 500
600 • 800 • 1000

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BENSON
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£3.00
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INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS FOR
PAKAWAY GAS FIRED AIR HEATERS

Models covered are:­

Single Phase Three Phase


100 VNG1 (standard) 100 VNG3 (optional)
150 VNG1 (standard) 150 VNG3 (optional)
200 VNG1 (standard) 200 VNG3 (optional)
300 VNG1 (standard) *300 VNG3 (optional)
400 VNG1 (optional) *400 VNG3 (standard)
500 VNG1 (optional) *500 VNG3 (standard)
600 VNG1 (optional) * 600 VNG3 (standard)
800 VNG3 (standard)
1000 VNG3 (standard)

THESE AIR HEATERS ARE FOR USE WITH NATURAL GAS ONLY

THEY MUST BE INSTALLED BY A COMPETENT PERSON

AS STATED IN THE GAS SAFETY REGULATIONS 1972

,; Pakaway, whose policy is one of continuous development and improvement, reserves the right to alter any
-~ specification appearing in this manual without notification.
If in any doubt on the interpretation of any instructions in this manual, please contact the Pakaway Sales
Office, address and telephone number as on back cover.
Appliances asterisked have been approved by British Gas for use on natural gas.
G.C. numbers:­
300 VNG3 42 534 01

.. 400 VNG3 42 534 02

. 500 VNG3 42 534 03

, . ..'. 600
~ .'
VNG3 42 534 04

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CONTENTS

Index Description Page no.

Section One - General


1A Introduction ..... . . .. .......... . .... . .... .. .. .... ...... . ... . .. . ...... ... ..... .. .......... 5

1B General requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1C Warranty ........ .. . .. . .. ..................... ... .................... . ...... . . . ...... . .. 5

1D Location .................................. .. . .. . . ...................... . ............... 6

1E Gas supply ........ .. . . . . . . .............. . .. . . .. ... . ...... , . . . . . . .. . . . . . . . . . . . . . .. . .. . . . 6

1F Boosted supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1G Flue system ....... . ...... . ................... . ................... . .. . .. . ............... 6

1H Air supply ............ . ......... . .......... . .................... . . ... .......... . ........ 7

1J Electrical supply . . . .. .... . .. . . . .. . .. .. ...... ... ... . . .. ... . .. . . . ... .. .... . .. . .. . ........ 7

Section Two - Installation of Air Heater


2A Heater unpacking . .. . . ....... " . .... ... ... . ... . . . . . . .. . .. . . . . . . . .. . . . . . . . . . . . ... ... . . . . 9

2B Installation clearances. . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . .. ... . .. .. .. . . . . 9

2C Connection of heater to flue system. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2D Gas connection .. ..................................................... .. ............... 9

2E Electrical connections . . . . . . . .. ...... .. ..... . .. . . . . . . ... ... . . .. .. . . . . . . . . . . ... .. .... . . . . 10

2F Electrical supply requirements ................... . ................ . , . . . . . . ... ...... . .. . 10

Section Three - Commissioning and Testing


3A Prel iminary precaut ions ..... . ... . ..... . . .. ..... . .................... .. ................ . 11

3B Control chassis check . .. ... . ......... . ......... . .. . .... . ........ . . .. . ... .............. . 11

3C Time switch chec.k .. ... .... . ............... . .... . . . . . ... . ........ ... . .. . .. .... . ... . ... . 11

3D Room thermostat check .. . ............... .. . . ............... . ... . .. . . . ....... . ........ . 11

3E Frost thermostat ... . .................... . . . . ... ............... . .... . . .. ............... . 11

3F Fan limit thermostat check ......................................... .. ................. . 11

3G Exp ~osion relief door check ............... .... . .. ..................................... . 11

3H Fan check ......... .. ................... . ... .. ........................ . ................ . 11

31 Flue pipe arrangement ...................... . .................... . .... . ............... . 12

3J Air supply check . ... .. ..................... . ......... . .............. . ................. . 12

3K Gas supply check . . . ... . .................. .... . . ................. . ..... . ........ . ..... . 12

3L Burner check up . . . ... .... . .............. . . . ........ . ............ .. .. . ................ . 12

3M Gas soundness testing of the gas line - Heater models 100 & 150 . . . ... .. ........ .. . . . 13

3N Gas soundness testing of the gas line - Heater models 200 & 300 VNG ... ..... . .... . . 14

30 Gas soundness testing of the gas line - Heater models 400 & 500 VNG3 ... . ......... . 15

3P Gas soundness testing of the gas line - Heater models 600, 800 & 1000 VNG3 ....... . 16

30 Gas soundness testing and setting of monobloc gas train ............................. . 17

3R Lighting the air heater . ...................... . ...................... . ................. . 18

3S Main burner gas pressure adjustment ... . ........................... . . . ............... . 18

3T Combustion check . .. . .............................................. ... ............... . 18

3U Air pressure switch setting ................ .. ....................... . .. . ............... . 18

3V Flame failure lock-out check .............. ... .................... . . .. ................. . 19

3W General .............................. . .. .. .. ... ..................... . ................. . 19

3X Users instructlions - Advice to user . .. . .. . . ... ........... . .... .. .... .. .... . ........ .. .. . 19

Section Four - Servicing


Servicing of air heater . . . . . . ... . . .. .. . . .......... . .. ........ ..... ..... ... . ... . ... .. .. . . . 21

Section Five - Fault Finding


Faults and remedies ............................................. . .. . .................. 23

Section Seven - Technical Data


7A Data sheets ...... . . . ....................... . ...................... ... ................. . 25

7C Electrode settings . .. .. ... ............... . . .. . . ..................... .. ...... . .......... . 26

7D Ionisation current ... . .. .. . . . ...... . ...... . . . . . .. . .. . ............ . . ... .... .. . . ...... . . . . 26

7E Combustion head adjustment - Gas 2 burner . . .. ... . . . ... . .... .. .. . ........... . . ... .. . 27

7F Air pressure switch adjustment ........ . ... ... ... . ........... . ...... .. ............ . ... . . 27

7G Mounting' - Gas 3 burner ............ . . . .. . .. . .......... . ............ . . . ..... . ........ . . 27

7H Combustion head adjustment - Gas 3 burner ......................................... . 28

7J Ti·m e switch setting . .................................................................. . 28

Section Eight - Wiring Diagrams & Commissioning Report


Three phase air heater wiring diagram ........................... . .. . .................. 31

Single phase air heater wiring diagram..... . . . . . . . .. .. .. . . . .. ..... . . . . .. .. . ... .. . .. . . . . 31

Commissioning check list ................. . ........................ .. .................. 34

Section One - General


1A INTRODUCTION
These instructions are intended to provide a guide to the procedure for a systematic check of the
msta't iation arrangements and of po~sible faults in the air heater arising during handling and 'i nstallation.
The Pakaway heaters are gas fired fanned circulation air heaters which have output ratings as shown in
the data sheet on page 25 and su~table for free-blowing and ducted applications.
The Pakaway heaters are to be floor-mounted and are primarily intended for heating and commercial or
industrial premises.
The fan, located on the base of the heater, is of doub ~e inlet centrifugal type.
The fully automatic forced draught burner is located on the front face of the heater and is complete with

pre-wired gas controls.

1B GENERAL REQUIREMENTS

Related Documents - Safety Note

The installation of the air heater(s) must be in accordance with the relevant requirements of the Gas

Safety Regulations, Building Regulations and the I.E.E. Regulations.

It should be in accordance also with any relevant requirements of the L.ocal Gas Region, Local Authority

and Fire Authority and t'he relevant recommendations of the British Standards Codes of Practice.

CP.331 Part 3:- Installation of pipes and Meters for Natulr al Gas.

CP.3 Chapter IV:- Precautions against fire.

British Gas Publication No. IM/11:- Flues for Commerciall and Industrial Gas Fired Boilers and Air Heaters.

British Gas Publication:- Combustion and Ventilation Air.

1WAH MA Publication No. 2:- Standards of Installation for Gas Fired Industrial Warm Air Heaters.

The above related documents are, from time to time, revised and additional documents published. Whilst

every effort is made to keep literature current, Pakaway cannot be responsible for this listing being correct

or complete at the time of issue.

1C WARRANTY

Please refer to the 'Conditions of Sale' printed on the reverse side of the Sales Acknowledgement, copies

of which can be supplied separately if requested from the Pakaway Sales Office.

Pakaway cabinet heaters are supplied backed by an extensive guarantee. The heater unit carries a

twenty-four month guarantee on all parts commencing from the wor'ks despatch date. In addition, the

combustion chamber/heater exchanger carries a ten year Time Related warranty.

The warranty is void if:­


(a) (i) The warranty registration/commissioning card has not been completed and returned to us within
fourteen days from delivery to site;
(ii) The first service registration card is not completed and returned to us within twelve montlhs from
the date that the registration/commissioning card was returned.
(b) Installation is not in accordance with the Codes and Standards listed in Section 1B General
Requi,rements of this manual.
(c) The flue arrangement and air supply for the heater is not in accordance with the recommendation or
codes of practice referred to in this manual.
(d) Air through heater is not provided in accordance with the technical specifications.
(e) Internal wiring on heater has been modified without Pakaway permission and/or written agreement.
(f) The main electrical supply input to the air heater has been switched on and off by other methods to
control heater, e.g. switched on and off via isolator.
(g) Heater has been affected by the ingress of water.
(h) The heater is not operated at the rating laid down in the technical data.
If a Claim Under Warranty is made then the following information is required to enable a replacement to
be supplied:
(i) Heater model
(ii) Heater serial number
(iii) Heater code number.
(This information, i.e. (i), (ii) and (iii) above, can be found on the data plate affixed to the front lower service
access panel of heater.)
(iv) Original order reference (where known) or approximate date of supply and full site address and
installer's name and address.
, (v) Information and symptoms regarding the alleged fault
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Faulty parts must be returned to Pakaway Sales Office for inspection to verify the claim.

I Note: Notification is required immediately a fault is suspected, otherwise no responsibility can be taken
for further damage, or expense incurred if other means are used to carry out rectification works.
5
10 LOCATION
The location chosen for the air heaters must permit the provision of a satisfactory flue system and an
adequate air supply. The location must also provide adequate space for servicing and air circulation
around the air heater.
The air heaters must be installed str~ctly in accordance with any fire regulations or insurance company's
requirements appertaining to the area in which the heater is located, particularly where special fire risks
are involved such as areas where petrol vehicles are housed, where cel'lulose spraying is carried out, in
woodworking departments, etc.
The air heaters must be installed on a level non-combustible surface which is capable of adequately
supporting the weight of the air heaters and any ancillary equipment. The heaters must be stable or rigidly
fixed in order to prevent hazard to personnel.
The air heaters must not be installed in conditions for which it is not specifically designed, e.g. where the
atmosphere is highly corrosive or salty and where high wind speeds may affect burner operation.
If the location of the air heater is such that it might suffer external mechanical damage, e.g. from overhead
cranes, fork lift trucks, it should be suitably protected.
Any combustible material adjacent to the air heater and the flue system must be so placed or shielded as
to ensure that its temperature does not exceed 65°C (150°F).

1E GAS SUPPLY
Service pipes
The local gas region should be consulted at the installation planning stage in order to establish the
availability of an adequate supply of gas.
An existing service pipe must not be used without prior consultation with the local gas region.
Meters
A gas meter is connected to the service pipe by the local gas region or a local gas region contractor.
An existing meter should be checked, preferably by the gas region, to ensure that the meter is adequate
to deal with the rate of gas supply required.
Installation pipes
Installation pipes should be fitted in accordance with British Standards Code of Practice No. CP331:3.
Pipework from the meter to the air heater must be of adequate size. Do not use pipes of smaller size than
the air heater gas connection.
The complete installation must be tested as described in the above code.

1F BOOSTED SUPPLIES
Where it is necessary to employ a gas pressure booster the controls must include a jow pressure cut-off
switch at the booster inlet.
The Ilocal gas region must be consulted before a gas pressure booster is fitted.

1G FLUE SYSTEM
Refer to British Gas Publication No.1 M/11 - Flues for Commercial and Industrial Gas Fired Boilers and
Air Heaters.
The Pakaway heaters do not require a draught diverter, they are supplied with an integral flue-box all owing
for the direct connection to an individual open-flue system.
Materials used for the flue system should be mechanically robust, resistant to internall and external
corrosion, non-combustible and durable under t he conditions to which they are likely to be subjected.
Prevention of condensation within the flue shou lld be an important factor in the design o~ the flue system.
In order to minimise condensation the use of double walled flue pipe or insulation is recommended. If
double walled flue pipe is used it shou ld be of a type acceptable to BriHsh Gas.
Where condensation in the flue is unavoidable provision should be made for the condensate to flow freely
to a point at which it can be released, preferably into a gully. The condensate pipe from the flue to the
disposal point should be of non-corrodible material of not I'ess than 22mm (%in) size.
Facilities should be made for disconnecting the flue pipe from the air heater for inspection and servicing
purposes. Bends with removable covers should be fitted for inspection and cleaning purposes where
considered appropriate.
The flue system should ensure safe and efficient operation of the air heater to which it is attached, protect
the combustion process from wind effects, and disperse the products of combustion to the external air.
The flue should terminate in a freely exposed position and must be situated so as to prevent the products
of combustion entering an opening in a building in such concentration as to be prejudicial to health or a
nuisance.
It i's recommended that a terminal be fitted at the flue outl'et.
6
1H AIR SUPPLY

Refer to ~tish Gas Publication - Combustion and Ventilation Air.


In all cases there must be provision for an adequate supply of air for both combustion and general
ventilation.
(a) Where heater is sited within area to be heated
So far as any ventilation requirements are concerned, the installer should take note of any mandatory
requirements for the provision of permanent air vents direct to outside. Any such air vents should
have negligible resistance and must not be sited in any position where it is likely to become easily
blocked or flooded nor in a position where it is possible for the i ngress of toxic or flammable vapour.
However, if the heater is sited within a building with an air infiltration rate of less than 0.5 per hour or
where the buil d ing volume is less than 2.2 m3 per KW of heater input, then ventilation should be
provided in accordance with the table of recommended minimum sizes.
(b) Where heater is si.t ed within a plant room or conf,i ned area
Where the heater is sited within a plant room or other confined area, then provision must be made for
the positive connection of either return air with high and low level ven tilation in accordance with
BS 6230 or if return air is through a louvre arrangement then the return air louvre must be of
adequate size so as not to starve the main air distribution fan of air in addition to which the
combustion air must enter through a duct which positively connects the burner combustion air fan to
outside. Under no circumstances must the burner be left to operate within an area of negative
pressure without a combustion air duct.
It is recommended that for applications such as (b) that you contact our Technical Department.
(c) Where the heater i's to operate within a toxic, corrosive or flammable atmosphere

Under these circumstances, please consult our Technical Department.

The basic minimum effective area requirement of the air vent is as follows:
Gas
heater model Air vent area per heater
I 100
150
180cm~
270cm~
(28in~)
(42in~)
200 360cm~ (57 in A)
A
300 523cm (80inA)
A
400 707cm (107inA)
A
500 883cm (134in~)
A
600 1060cm (160inA)
A A

800 1450cm (219in )

1850cm (280in~)
A

1000

1J ELECTRICAL SUPPLY
Wiring external to the air heater must be installed in accordance witlh I.E.E. Wiring Regulations and any
local regulations which apply.
Models 100 to 300 are normally supplied for 240 volts, 50Hz, single phase, neutral and earth.
Models 400 to 1000 are normalily supplied for 415 volts, 50Hz, 3 phase, neutral and earth.
The method of connection to the mains electricity supply must facilitate complete electrical isolation of
the air heater by an isolator having a contact separation of at least 3mm in all poles for three phase and
1.5m separation on single phase and the supply must serve only the air heater. The method of connection
should be provided adjacent to the air heater in a readily accessible position.
For wiring instructions see page 31 .

7
GENERAL ARRANGEMENT OF CABINET & ACCESSORIES

Flue Pipe

~~~~~_-----------..,-- Air Nozzles

,b::!:::::::::==:::::====r~~~~~;;:=~:;;~------- Fan Limit Thermostat

HHI----J--+H-l----- H eat Exchanger

1--~____--~f-__I--+tH---- Air Deflectors

---4,-Ht--+--­ - ­ Combustion Chamber

Burner

r?7iiK\--if::+------ Room Thermostat

~=-=:.-..-::-,++----- Ti me Clock

Control Chassis
Thermal
Insulation
Mark II
Air Inlet Panel

Ventilated
Heat Shield Main Fan Drive Motor (Indirect Drive)
on Mark II I
Direct Drive Fans fitted on mode ls 100 to 300

Main Air Distribution Fan

8
Section Two - Installation of A,i r Heater
2A HEATER UNPACKING
The air heaters are despatched as follows:
1) Air heater complete with burner and flue box, all protected by plastic sheeting.
Note: Gas train may be disconnected from the burner and stowed in the heater fan compartment.
2) Air heater to~ plate dispatched separately. } N t I' ble t d ct head models.
3) Air nozzles dispatched separately. 0 app Ica 0 u

After heater is correctly positioned, locate heater top plate over spigot provided and then place air nozzles
over outlets in top plate.
The air heater is to be floor-mounted on a level non-combustible surface which is capable of carrying the
weight of the air heater and any ancillary equipment. See data sheet on page 25.

28 INSTALLATION CLEARANCES
The space in which the heater is to be fitted must have the following minimum dimensions:­
Heater model Width Depth Height
100 & 150 1000mm (40in) 1525mm (60in) 2800mm (110in)
200 & 300 1000mm (40in) 2000mm (80in) 3000mm (120in)
400 & 500 1400mm (55in) 2200mm (87in) 3500mm (138in)
600 1400mm (55in) 2600mm (104in) 3650mm (144in)
800 1650mm (65in) 2450mm (98in) 3950mm (155in)
1000 1650mm (65in) 2550mm (102in) 3950mm (155in)
In addition to the dimensions mentioned above the following minimum clearances must be available at the
front of the heater on heater models 800 and 1000, at the back of the heater also on heater models 100
to 600 to enable heater to be serviced.
Heater model Clearance
100 & 150 760mm (30in)
200 & 300 1000mm (40in)
400 & 500 1000mm (40in)
600 1000mm (40in)
800 1270mm (50in)
1000 1270mm (50i n)

2C CONNECTION OF HEATER TO FLUE SYSTEM


The heaters do not normally require a draught stabiliser, as they are supplied with an integra~ flue-box
allowing for the direct connection to an individual open flue system.
The flue pipe disposes of the gases from the burner and its correct functioning is a most vital part of the
heater.
Make sure the flue pipe is sealed into the socket on the heater and elsewhere using a suitable sealant

material. If a draught stabiliser is fitted, check that it is in the closed pOSition. Check that it is free to move

and not prevented from swinging by foreign objects or damaged in any way.

It Is imperative that where a flue passes through roof, this opening is properly sealed by roof plate
and cravat to ensure no water e nters.
NO CLAIMS FOR ANY DAMAGE RESULTING FROM INGRESS OF WATER WILL BE CONSIDERED.
Flue pipes must not have sharp bends. Easy obtuse bends are necessary to assist the flow of gases. Flue
terminal cowls as demanded by site conditions are necessary.
Care must be taken that the flue height and materials used, meet all the necessary requirements and
codes. (Refer to General Requirements on page 5 of these instructions.)

20 GAS CONNECTION
Heater models 100, 150, 200, 300, 400 & 500
Fit burner gas train to burner at union connection on the underside of blast-tube, the gas train can be
positioned for either left or right hand gas supply pipe connection.
Fit the two electric plugs on the flying leads from the gas train into the sockets located on the back face of
the burner, these plugs are not interchangeable.
Heater model 600, 800, 1000
Fit burner gas train to burner at flange connection on the underside of blast-tube using gasket and fixings
·supplied. The gas train can be positioned for either left or right hand gas supply pipe connection.
Fit the three electric plugs on the flying leads from the gas train into the sockets located on the underside
of the burner housing. (Note: The 3 pin plugs on the pilot gas valves can be safely interchanged.)
The gas pipework should be sized to produce the required gas volume so that at least the minimum inlet
pressure (see page 25) is obtained to the burner manifold, to give the required head pressure.
9
The local gas region prefer to be consulted regarding each installation and they will advise as to the
pressure of gas supply and the recommended pipe sizes for single or multi-heater installations.
Note: Each heater must be fitted with a gas supply isolating cock and a suitable union. (The cock to be
upstream and adjacent to the union which in turn must be upstream of the burner outlet.)
These items can be supplied as an optional.
Under no circumstances must the gas pipework be used as an electrical earth.

2E ELECTRICAL CONNECTIONS
Note: All electrica'i wiring and connections must be made in accordance with the I.E.E. regulations. Check
any local regulations that apply, Le. garage installations or hazardous environments.
Check rating plate on heater for supply voltage requirements. Connect supply from a suitably fused
isolator or a local isolator on a suitably fused supply to the mains terminal strip in the wiring chassis of the
air heater (see wiring diagram on page 31).
Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.
All external wiring must be enclosed within approved conduit. Conduit from isolator switch must run so as
not to interfere with service panels of the air heater.
Whether a single heater or a number are to be wired as part of a single installation, an isolator must be
provided, so that each heater can be separately d,i sconnected. The isolator switch shouId be located in a
readHy accessible position. Each heater should be independently fused.
Controls from one heater to another heater must not be interwired.

2F ELECTRICAL SUPPLY REQUIREMENT


Model 100 - 300 15 amp single phase (optional- 10 amp three phase)
Model 400 - 600 15 amp three phase and neutral (optional- 30 amp single phase)
Model 800 & 1000 30 amp three phase and neutral
Check voltage on nameplates agrees with electrical supply.
Time switch, roomstat and froststat
These are supplied as an integral part of the air heater, refer to Commissioning Instructions.

I~
r,
I
IiIi
Section Three - Commissioning and Testing
3A PRELIMINARY PRECAUTIONS
All heaters must be commissioned. test fired and serviced by a competent gas engineer.
a) Before attempting any check; switch off electrical supply to heater at main isolating switch
and remove fuses.
b) Shut off main gas isolating cock to unit.
Note: The unit is·not isolated electrically until the main isolator is switched off and the fuses are removed.
Switchi,ng off at the summer/winter switch ils not sufficient when work is being carried out on the unit.

3B CONTROL CHASSIS CHECK

Remove screws retaining front air inlet panel and remove panel for access to wiring chassis.

Check that all wires on control chassis are secure, and tHat no strands of multi-strand cables are near, or

bridging across terminals or to earth.

Check that reset buttons operate freely.

3C TIME SWITCH CHECK

Aqjust time switch for required ON/OFF sequence.

Refer to page 28 for setting instructions.

3D ROOM THERMOSTAT CHECK

The operation of the room thermostat can be checked as follows:­


With the indicator set to the high limit of the scale and the burner firing, slowly reduce the scale setting, at
actual room temperature, the burner should shut down. After the test the room thermostat should be set to
the temperature required.

3E FROST THERMOSTAT
This is wired across switched circuit by-passing the time switch control and wil l not effect commissioning
and testing whilst time switch is on ON cycle.

3F FAN LIMIT THERMOSTAT CHECK

Check and ensure that the combination fan I'imit thermostat settings are as specified below:

FAN OFF = 30°C (86°F)

FAN ON = 60°C (140°F)


LIMIT = 120°C (250°F)
Make sure the combination control is set to auto Le. white button pulled outwards. Some models also have
a RED reset button. Push to reset If this red reset button requires operating during normal service of the
heater, the cause should be determined and rectified as soon as possible to avoid possible damage to the
heater.
These settings must not be increased, although the fan ON and fan OFF can be lowered if desired.

3G EXPLOSION RELIEF DOOR CHECK

Check that the door is free to open and that it is not obstructed in any way by piping etc.

3H FAN CHECK

Important: First isolate electrical supply and remove fuses.

Remove screws retaining air inlet panel and remove panel for access to fan.

Rotate fan by hand to check that it is running freely, and that it is free from foreign bodies in the fan

blades.

Check pulley tightness on shafts.

Check fan belt tension which should give approximately 6mm (1/4in) belt movement up and down at mid­
001 t. Adjust by moving motor on slide rails.
Jc k tightness of fan shaft bearing locking coHars.

Replace air inlet panel and retaining screws.

Replace fuses and switch on e.l ectrical supply to unit.

Check rotation of fan.

,,

Move summer/winter switch to 'Summer' to run fan only. Fan should run in direction giving the most air

volume from the unit. If it runs in the reverse direction, return switch to OFF, turn off electrical supply at

. main isolating switch and remove fuses. Then reverse any two of the incoming phases at the heater
terminal block. Replace fuses. Turn on isolator. Check again for correct rotation. Return switch to OFF
position.
Models 100/300 have single phase direct drive fan units. Check details as applicable.

31 FLUE PIPE ARRANGEMENT


Check that the flue pipe arrangement has been carried out in accordance with the design requirements.

Refer to section on 'Connection of Heater to Flue System' on page 9 of this manual.

Check flue pipe joints at heater and elsewhere.

Check for flue obstruction.

3J AIR SUPPLY CHECK


The heater requires air for combustion and for heating the building.
It is important to check to ensure that the installation work has been carried out in accordance with the
design requirements, paying particular attention to the air requirements stated in the section on Air Supply
on page 7 in this manual.
If there is any doubt on this matter consult Pakaway, address and telephone number as on back

cover of this manual.

3K GAS SUPPLY CHECK


Check that type of gas being used is correct for burner. Heaters are supplied with burners suitable for

natural gas unless otherwise specified.

Check main burner isolating gas tap operates freely. Open and close by hand.

Check supporting arrangements of the pipeline to ensure that lines are correctly supported and that

unions are not strained by excessive lengths of free pipe.

The whole of the gas installation incl uding the meter, should be inspected and tested for soundness and

purged in accordance with the recommendations of British Standard Code of Practice 331 :3.

3L BURNER CHECK UP

Turn OFF gas at main isolating tap and electrical supply at main isolating switch.

Reillo gas burner on heater models 100, 150, 200, 300, 400 & 500

Remove the burner cover by loosening the three retaining screws and then pull cover away from burner.

Remove the two electrical plugs (one plug on models 100/150) on the flying leads from the gas train from

the sockets on the back face of burner.

Remove top of burner fan housing by undoing securing screw, this gives access to the leads to the

electrode and flame probe.

Remove leads from the electrode and flame probe, tlh e burner can now be separated from the blast tube
and firing head by loosening the nut and turning the latch at the top front of the blast tube.
Remove the socket head screw (1) on page 27 and remove firing head (2) from blast tube (Section 7E).
Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked
in the factory and should not require re-setting. Replace firing head (Section 7C).
Firing head setting
Two separate adjustment settings have to be made; one for the air and one for the gas. Refer to table on
page 25 for setting numbers.
Method for air-setting (Refer page 25, Section 7 E)

Loosen the screw (1), move the firing head (2) so that its rear edge (3) is level with the desired setting

number on the page (4). Then tighten the screw (1).

Method for gas setting (Refer page 25, Section 7E)

Loosen the screw (5), move the ring (6), so that the pointer (7) is level with the desired setting number (8).

Then tighten the screw (5).

Replace the burner to the blast tube and replace latch and tighten nut.

· Replace Il eads to electrode and flame probe and replace fan housing cover.

Replace the electric plugs on the flying leads from the gas train into the sockets located on the back face

of the burner, these plugs are not interchangeab e.

Ensure that electrical connections to burner and controls are secure.

, ?
Reillo gas 3 burner on heater model 600, 800 & 1000

Remove the three electric plugs on the flying leads from the gas train from the sockets on the underside

of the burner housing.

Separate the firing head from the rest of the burner by removing the two screws (1) on page 27 and

withdrawing the burner body on the holding-bars (2) (Section 7G).

The action of puHing the burner-body from the firing head will release the leads from the electrode and

flame probe.

Remove the two socket head screws (1) on page 28 and remove firing head (2) from blast tube

(Section 7H).

Check that the ignition electrode and flame probe are positioned as shown in page 26. These are checked

in the factory and should not require re-setting (Section 7C).

Replace firing head.

Firing head setting

Two separate adjustments have to be made; one for the air and one for the gas. Refer to table on page 25

for setting numbers.

Method for air setting (Refer page 28, Section 7H)

Loosen the two screws (1) and move the firing head (2) so that it's rear edge (3) is level with the desired

setting number on the plate (4).

Then tighten the screws (1).

Method of gas setting (Refer page 28, Section 7H)

Loosen the screws (5), move the ring (6) so that the pointer (7) is Ilevel with the desired setting number (8).

Then tighten the screws (5).

Replace the burner-body to the blast tube making sure the leads to the electrode and flame probe are re­

connected, the use of pliers will help in connecting the two leads. Replace the two securing screws.

Replace the electric plugs on the flying leads from the gas train into the sockets located on the underside

of the burner housing. (Note: the 3 pin plugs on the pilot gas valves can be safely interchanged.)

Ensure that electrical connections to burner and controls are secure.

EstabHsh type of gas train fitted, that is conventional or CG Monobloc. Use appropriate testing scheme.

3M GAS SOUNDNESS TESTING OF THE GAS TRAIN - HEATER MODELS 100 & 150

T cr::::::>>+-I--~c:>tJ· :f c:G1------~f-------.-
A, B Manual shut off valves

1 Main governor

2 Safety shut off valve

3 Operating valve

1. Switch off the heater. Isolate the electrical supply and close manual gas valves A & B.
Testing the pipework up to the upstream safety shut off valve
2. Connect a water column pressure gauge to pressure test point P1.
3. Open valve A to pressure the assembly up to the seat of the safety shut off valve.
4. Close valve A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If pressure
falls, open valve A and test for leaks with soap solution. Make good as necessary and recheck. Note:
Two minutes should be allowed for all soap solution tests.
Testing upstream safety shut off valve
5. Close valve B and open valve A Connect the pressure gauge to test point P2. If a rise in pressure is

observed then the safety shut off valve seat is paSSing. Make good and recheck.

Testing downstream operating valve .


6. link pressure test points P1 and P2 with rubber tube and a tee piece. Connect the pressure gauge to
the tee piece. Open valve A and valve B. Then close valve A If a drop is observed then either the
downstream operating valve is passing or the pipework between the safety shut off valve and the
operating valve is leaking.
7. Close valve B, open valve A and test the enclosed pipework for leaks with soap solution. Make good

and retest.

8. If the pipework is not leaking then the operating valve seat is paSSing. Make good and retest.
13
3N GAS SOUNDNESS TESTING OF THE GAS TRAIN - H'EATER MODELS 200 & 300

A, B& C Manual sh ut off valves


1 Main governor
2 Upstream safety shut off valve
3 Downstream safety shut off valve
4 Pilot safety shut off valve
5 Pressure test points

Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off valve
2. Connect a water column pressure gauge to pressure point P1.
3. Open valve A to pressurise the governor assembly.
4. Close A. Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls. open A and test for leaks with soap solution. Make good as necessary and recheck.
Note: Two minutes should be allowed for all soap solution tests.
5. If no external leaks are observed, the upstream safety shut off valve is passing.
To check this remove the screw from pressure test point P3 and depressurise the space between the
safety shut off valves.
Connect the water column pressure gauge and leave for 2 minutes with A still open. A rise in
pressure confirms the first valve is passing. Make good and recheck for soundness.
Testing the downstream safety shut off valve & pilot safety shut off valve
6. Close valve A and connect pressure test points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the assembly up to the seats of the downstream safety shut off valve and
pilot safety shut off valve.
8. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
faUs, open A and test the pipework connecting the safety shut off valve for leaks with soap solution.
Make good as necessary and recheck.
9. If no external leaks are observed either the downstream safety shut off valve or the pilot safety shut
off valve is passing. To check this remove the screw from pressure test point P4 and depressurise the
downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P4
and leave for 2 minutes with A still open. A rise in pressure confirms the downstream safety shut off
valve is passing. Make good and recheck for soundness. Then remove the pressure gauge from test
point P4 and connect to test point P6 and leave for 2 minutes with A still open. A rise in pressure
confirms the pilot safety shut off valve is passing. Make good an d recheck for soundness.
Testing the downstream pipework
10. Close valve A and connect pressure test points P2 and P4 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure

falls, open A and test for leaks in the pipework downstream of the safety shut off valves with soap

solution. Make good as necessary and recheck.

Testing the downstream pilot line pipework


13. Close valve A and connect pressure paints P2 and P6 with a length of rubber tubing. Connect the

pressure gauge to test point P1.

14. Open valve A to pressurise the line to valve C.


15. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open A and test for leaks in the pipework downstream of the pilot safety shut off valve with soap
solution. Make good as necessary and recheck.
30 GAS SOUNDNESS TESTING OF THE GAS LINE HEATER MODELS 400 & 500 VNG3

A
P5

A,B&C Manual shut off valves


1 Main governor
2 Upstream safety shut off valve
3 Downstream safety shut off valve
4 Pilot safety shut off valve
5 Pressure test paints
Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off and pilot safety shut off valves
2. Connect a water column pressure gauge to test point P1.
3. Open valve A to pressurise the assembly up to the seats of the upstream safety shut off and pilot
safety shut off valves.
4. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
faUs, open A and test for leaks with soap solution. Make good as necessary and recheck. Note: Two
minutes should be allowed for all soap solution tests.
5. If no external leaks are observed either the upstream safety shut off valve or the pilot safety shut off
valve is paSSing. To check this remove the screw from pressure test point P3 and depressurise the
downstream pipework. Remove the pressure gauge from test point P1 and connect to test point P3
and leave for 2 minutes with A still open. A rise in pressure confirms the upstream safety shut off
valve is paSSing. Make good and recheck for soundness. Then remove the pressure gauge from test
point P3 and connect to test point P6 and leave for two minutes with A still open. A rise in pressure
confirms the pilot safety shut off valve is paSSing. Make good and recheck for soundness.
Testing downstream safety shut off valve
6. Close valve A and connect pressure points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the line up to the seat of the downstream safety shut off valve.
8. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open A and test for leaks in the pipework between the safety shut off valves with soap solution
Make good as necessary and recheck.
9. If no external leaks are observed, the downstream safety shut off valve is passing. To check this
remove the screw from pressure test paint P4 and depressurise the downstream pipework. Remove
the pressure gauge from test point P1 and connect it to test point P4 and leave for 2 minutes with
valve A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make
good and recheck for soundness.
Testing the downstream main-line pipework
10. Close valve A and connect pressure test points P2 and P4 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open A and test for leaks in the pipework downstream of the safety shut off valves with soap
solution. Make good as necessary and recheck.
Testing the downstream pilot line plpework
13. Close valve A and connect pressure test points P2 and P6 with a length of rubber tubing. Connect the
pressure gauge to test paint P1.
14. Open valve A to pressurise the line to valve C.
15. Close A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open A and test for leaks in the pipework downstream of the safety shot off valves with soap
solution. Make good as necessary and recheck.
3P GAS SOUNDNESS TESTING OF THE GAS HEATER MODELS 600, 800 & 1000 VNG3

A B

P1
P5

3 4

A,B&C Manual shut off valves


1 Multifunctional gas control incorporating the main governor and up and downstream
shut off valves
2 Pilot line governor
3 Upstream pilot safety shut off valve
4 Downstream pilot safety shut off valve
5 Pressure test points
Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A, Band C.
Testing the pipework up to the upstream safety shut off and pilot shut off valves
2. Connect a water column pressure gauge to pressure test point P1.
3. Open valve A to pressurise the assembly up to the seats of the upstream safety shut off and
upstream pilot safety shut off valves.
4. Close valve A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the
pressure falls, open valve A and test for leaks with soap solution. Make good as necessary and
recheck. Note: Two minutes should be allowed for aU soap solution tests.
5. If no external leaks are observed either the upstream safety shut off valve or the upstream pilot safety
shut off valve is passing. To check this remove the screw from pressure test point P3 and
depressurise the downstream pipework. Remove the pressure gauge from test point P1 and connect
to test point P3 and leave for 2 minutes with valve A stil l open. A rise in pressure confirms the
upstream safety shut off valve is passing. Make good and recheck for soundness. Then remove the
pressure gauge from test point P3 and connect to test pOint P7 and leave for 2 minutes with valve A
still open. A rise in pressure confirms the upstream pilot safety shut off valve is passing. Make good
and recheck for soundness.
Testing downstream safety shut off valve
6. Close valve A and connect pressure test points P2 and P3 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
7. Open valve A to pressurise the line up to the seat of the downstream safety shut off valve.
8. Close valve A Leave system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open valve A and test for leaks in the pipework between the safety shut off valves with soap
solution. Make good as necessary and recheck.
9. If no external leaks are observed, the downstream safety shut off valve is passing. To check this
remove the screw from pressure test point P4 and depressurise the downstream pipework. Remove
pressure gauge from test point P1 and connect to test point P4 and leave for 2 minutes with valve A
still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good and
recheck for soundness.
Testing the downstream plpework
10. Close valve A and connect pressure test pOints P2 and P4 with a I,ength of rubber tubing. Connect the
pressure gauge to test point P1.
11. Open valve A to pressurise the line to valve B.
12. Close valve A Leave the system for 2 minutes and watch for a fall in pipework pressure. If the
pressure falls, open valve A and test for leaks in the pipework downstream of the safety shut off
valves with soap solution. Make good and recheck.
Testing downstream pilot safety shut off val,ve
13. Close valve A and connect ,pressure test points P2 and P7 with a length of rubber tubing". Connect the
pressure gauge to test point P1.
14. Open valve A to pressurise the pipework up to the seat of the downstream pilot safety shut off valve.
15. Close~lve A Leave the system for 2 minutes and watch for a falj in pipework pressure. If the
pressure falls, open valve A and test for leaks in the pipework between the safety shut off valves with
soap solution. Make good as necessary and recheck.
16. If no external leaks are observed, the downstream pilot safety shut off valve is passing. Tb check this
remove the screw from pressure test point P1 and depressurise the downstream pipework. Remove
the pressure gauge from test point P1 and connect to test point IP8 and leave for 2 minutes with valve
A still open. A rise in pressure confirms the downstream safety shut off valve is passing. Make good
and recheck for soundnes&
Testing the downstream pilot line pipework
17. Close valve A and connect pressure points P2 and P8 with a length of rubber tubing. Connect the
pressure gauge to test point P1.
18. Open valve A to pressurise the line to valve C.
19. Close valve A Leave system for 2 minutes and watch for a fall in pipework pressure. If the pressure
falls, open valve A and test for leaks in the pipework downstream of the safety shut off valves with
soap solution. Make good as necessary and recheck.

30 GAS SOUNDNESS TESTING & SETTING OF MONOBLOC GAS TRAIN

A P1 P2 P3 B

--,.~.--~~---~~===c:I==r1~__~~-r=~~~.~_
A, B Manual shut off valves
P1, P2, P3 - Pressure test pOints
C Main block
Procedure
1. Switch off the heater. Isolate the electric supply and close manual gas valves A & B.
Testing the upstream pipework to the block
2. Connect a water column pressure gauge to P1.
3. Open A to pressurize to block.
4. Close A. Leave for 2 minutes. If pressure falls test for leaks with soap solution between A and block.
Make good as necessary and recheck.
Note: Two minutes should be aillowed for all soap solution tests.
Testing the first stage valve
5. Connect water column pressure gauge to P2 and open A If a pressure rise is observed the first stage
valve seat is passing. Rectify or replace and recheck.
Testing the downstream pipework for the block
6. Close A. link P1 and P3 with rubber tube and via a T piece connect a water column pressure gauge.
Open A to pressurize the system. Close A and leave for two mi,nutes. If a fall in pressure is observed,
test for leaks between the block and B. Make good as necessary and recheck.
Testing the second stage valve
7. Link P1 and P2 with rubber tube. Connect water column pressure gauge to P3. Open A If a pressure
rise is observed then the second stage is passing. Rectify or replace and recheck.

~I
I
ST HOLD SCREW

PS PG
17
Use 2.5mm Allen Key to adjust - DO NOT FORCE.
PS - Adjust the start gas pressure
PG - Adjust the main gas pressure
ST - When released 1-2 turns holds the control on start gas rate
Initial start of burner and adjustment
1. Release screw ST 1-2 turns.
2. Set control PS to a low value on scale and ensure control PG is set to a low value but slightly greater
value than that of control PS.
3. Start burner and set control PS to give an increase in pressure of 0.5" wg. (1.25 mbar) at the burner
head over the proving air value.
4. Close screw ST.
5. Set control PG to give specified burner head pressure.
The transfer from start to main gas is automatic and occurs 5-7 seconds after PS is energised or 5-7
seconds after screw ST is closed.

3R LIGHTING THE AIR HEATER


When all the commissioning checks have been completed the following procedure should be adopted for

lighting the burner and carrying out combustion checks.

i) Open all gas valves.

ii) Set the time switch to an 'ON' cycle.

iii) Ensure that the thermostat(s) are calling for heat

iv) Set summer/winter switch to 'Winter' position.

v) Switch on the mains electricity supply to heater. The heater should now start.

The normal burner start-up cycfe is as follows:­


Thermostats etc.

Motor

Ignition transformer

Start gas valves

Start gas flame

Main gas valve

Main flame

If main flame cannot be established, then contact Pakaway.


Do not attempt to open the burner control box as once the seals are broken the guarantee is void.
After a flame has been established check for gas soundness around the air heater gas components using
a leak detection fluid.

3S MAIN BURNER GAS PRESSURE ADJUSTMENT


After the burner has been firing for at least 10 minutes check the gas pressure at the burner head is as

listed -in data sheet on page 25. Adjust the pressure if necessary at the gas governor in the gas train line

or on the monobloc if fitted.

The main burner pressure test point is located at the side of gas inlet to the burner head.

3T COMBUSTION CHECK
When the correct gas pressure has been established, adjust the combustion air shutter at the burner to
give carbon dioxide (C02) reading at the flue outlet of 8.5 to 9.0%.
Secure the air shutter.
The flame can be viewed from the viewing port on the burner or from the explosion relief door on the back
face of the heater on models 100 to 600 and on front face of heater on 800 and 1000 models. Care
should be taken when doing this as it is a pressurized combustion chamber.
IdeaUy the burner flame should be close to the burner head, pale blue in colour and have sl'ightly whitish

yellow tips to the flame end. The flame must not impinge on the end or side of the combustion chamber.

3U AIR PRESSURE SWITCH SETTING


Adjust the setting of the air pressure switch after all other adjustments have taken place, starting from the
sett ing at the bottom of the scale.
While the burner is firing, increase the pressure by slowly turning the regulating knob clockwise until gas

valve closes.

Then turn the knob back by two turns and restart the burner, thereby checking that it functli ons correctly,

should the burner again go to lockout, turn the knob back by one more full turn.

3V FLAME FAILURE LOCK-OUT CHECt'


I'f flame fai l ure occurs when the burner is firing lock-out should take place within one second.
To check this turn off the main gas supply isolating valve whilst the burner is firing and the neon light in
the burner control, box reset button should come on immediately.
To restart burner, open gas isolating valve and press burner control box reset button, the burner will then
go through the normal start-up cycle.

3W GENERAL
When all checks are complete replace the burner cover and tighten the three retaining screws. Finally
recheck the combustion to make sure that the fitting of the burner cover has not altered any conditions.
Re-adjust all controls to suit customers requirements.
Note: During all tests when the burner is firing the main heater fan operates independently under control
of the fan thermostat.

3X USER INSTRUCTIONS - ADVICE TO USEIR


Upon satisfactory completion of commissioning and testing hand the User's Instructions to the user or
purchaser and explain the method of economic and efficient operating of the system.
Ensure that the user or purchaser is fully conversant with the lighting, shut down and general operational
procedure.
Advise the user or purchaser that for continued efficient and safe operation of the air heater, it is
important that adequate servicing is carried out at regular intervals.
Replace the burner-body to the blast tube making sure the leads to the electrode and flame probe are re­
connected, the use of pliers will help in connecting tlhe two leads. Replace the securing screws.
Replace the electric plugs on the f,lying leads from the gas train into the sockets located on the underside
of the burner housing. (Note: The 3 pin plugs on the pilot gas valves can be safely interchanged.)
Remove the top burner cover to give access to burner controls and wiring and check all the electrical
connections are secure.
Replace top burner cover.
4. Testing

When servicing is completed, replace the fuses and switch on main electric supply.

Check gas soundness of the gas line as described on pages 13 to 16.

Light the heater and carry out all the tests as described in the Commissioning and Testing Instructions.

Quote heater model, serial number and code number when ordering spare parts.

Section Four - Servicing of Air Heater


The air heater is constructed to give long trouble free service, but in common with all mechanical
apparatus, it needs periodic attention.
The following routine of maintenance checks should be carried out annually, preferably before
commencement of the heating season.
Before commencing maintenance, isolate heater as follows:
Set summer/winter switch to 'OFF' position. Turn off main gas isolating valve. Switch off main electric
supply isolator and remove fuses.

1. Clean flue box and heat exchanger unit

Remove the access covers on the flue box and brush the flue ways, flue box and flue system.

Remove all loose carbon material before replacing the access covers.

2. Clean main fan and housing and check fan belt tensions

Remove front and back air inlet pane,ls for access to fan housing.

Clean main fan of dust, paper etc. and check bearings for wear.

Check tightness of belts, pulleys on fan and motor shafts, tighten set screws if necessary.

Check fan belt tension which should give approximately 6mm (1f4in) belt movement up and down at mid­

point. Adjust by moving motor on slide rails.

If all adjustment is taken up replace belt(s).

Note: Some units are fitted with direct drive main fans - if so, omit only the above references to belts and

pulleys.

Replace back air inlet panel.

Before replacing front air inlet panel examine the electrics for loose connections and check reset button(s)

operate freely.
Replace front air inlet panel.

3. Burner servicing
Riello Gas burner on heater modells 100, 150, 200, 300, 400 & 500
Remove the electric plugs on the Hying leads from the gas train, from the sockets on the back face of the

burner.

After removing the burner cover, remove top of burner fan housing by undoing securing screw. This gives

access to the electrode and flame probe leads.

Remove these leads and the burner can now be separated from the blast tube by loosening the nut and

turning the latch at the top front of the blast tube.

Remove the socket head screw and remove firing head from the blast tube. Brush clean if necessary.

Check that the ignition electrode and flame probe are pOSitioned as shown on page 26, also clean

electrodes and check porcelains for hairlline cracks, dust and carbon.

Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the Commissioning

and Testing Instructions.

Replace the burner to the blast tube and replace latch and tighten nut.

Before replacing leads to electrode and flame probe make sure the burner fan ,housing and all burner

components are clean and free of dust.

Re-connect the plugs on the flying leads from the gas train into the sockets on the burner.

Examine all the electrical connections to burner and controls.

Riello Gas 3 burner on heater model 600, 800, 1000

Remove the three electric plugs on the flying leads from the gas train, from the sockets on the underside

of the burner housing.

Separate the firing ,h ead from the rest of the burner by removing the securing screws and withdrawing the

burner-body on the holding bars.

The action of pulling the burner-body from the firing head will release the leads from the electrode and

flame probe.

Remove the two socket-~ead screws and remove firing head from the blast tube.

Check that the ignition electrode and flame probe are positioned as shown in page 26. Also clean

electrode and check porcelains for hairline cracks, dust and carbon.

Replace firing head and adjust as described in the 'Burner Check Up' on page 12 in the CommisSioning

and Testing Instructions.

21
Section Five - Fault Finding
FAULTS AND REMEDIES
Before making any adjustments ensure that the burner is electrically isolated.
Burner fails to start
1. One of the controls in the circuit not making contact such as the time switch, room thermostat, limit
thermostat or the air pressure switch.
2. Burner control box locked-out.
3. Check electrical supply.
Burner starts, fails to light and locks-out
1. Check gas supply, gas va lves and pressure settings. Re-purge if necessary.
2. No spark at electrode. Check electrode setting.
3. Spark does not ignite gas. Check electrode setting.
4. Check for flue blockage.
Burner motor starts, but not the control box sequence
11. The air pressure switch does not close its contacts. Check setting of air pressure switch. Replace if
defective.
Burner ignites and then locks-out
1. Flame probe incorrectly set. Check setting.
2. Excessive combustion air causing flame to lift off burner head.
3. Insufficient gas. Check gas supply.
4. Gas pressure too high. Check gas rate and pressure.
5. Check air pressure switch.
6. Check earth connections are secure and wired correctly to a good earthing source.
Burner locks-out during pre-purge or after shutdown
1. Flame sensed, ch eck gas valves.
2. Check control b ox, replace if defective.
Burner pu ,l sates when running
1'. Overiiring. Check gas rate.
2. Incorrect mixture. Adjust burner.
Insufficient air supply from main fan
1. Loose or worn fan belt(s), pulleys insecure.
2. Incorrect fan rotation (three phase). See page 11, Section 3H - Fan Check.
3. Air inlets obstructed.
4. Fan blades choked.
5. Excessive external air resistance.
Noisy main fan
1. Loose or worn fan belt(s).
2. Loose or worn bearing locking caps.
3. Worn bearings.
4. Pulleys insecure.
5. Paper etc. in fan causing imbalance.
6. Worn or dry motor bearings.
7. Loose fan support.
Fan starts when isolating switch is turned on but summer/winter is in OFF position
1. Make sure the fan limit combination is set to auto, i.e. white button pulled outwards.

22
Section Seven - Technical Data
7A DATA SHEET MK II Sept. 1987
HEATER MODEL 100 150 200 300 400 500 600 800 1000

I RIELLO GAS 3
GAS H GAS I GAS I GAS 2 GAS 2 GAS 2 GAS 3 GAS 3
BURNER TYPE

BURNER mbar 3.68 4.9 6.1 4.9 6.1 7.2 6.8 6.86 8.09
GAS SETTING
PRESSURE ins.wg. 1. 5 I 2.0 2.5 2.0 2.45 2.9 2.73 2.8 3.3

BURNER AIR
N/A 2 2.75 1 3 5 1 3 3
SETTING
1
BURNER GAS
2 2 2.75 0 3 4 0 7 7
SETTING

kW 40.4 54.65 75.72 116.2 150.3 188.4 226 .5 311 .5 390.4


HEAT
,
INPUT 137.862 772.700 1.061 ,910 1,331 .010
Btu/h 186.300 253.368 396.500 512.820 642.800

kW 30.6 44.0 56.2 146.5 175.8 234.0 293.0


HEAT 87.9 1 117.2
OUTPUT Btu/h 112,000 800,000 1,000,000
150.000 202,060 300,000 400,000 500,000 600.000

BURNER GAS 34" BSP 1" BSP 1" BSP 1V2" BSP
'12 " '12 " '12" 1" BSP 1" BSP
INLET EXT INT INT INT
EXT EXT EXT EXT EXT
CONNECTION

mm 152 152 200 200 200 200 250 250 250


FLUE
SIZE ins. 10 10 10
6 6 8 8 8 8

MIN INLET mbar 12.5 10.29 13.48 14.0 113.0 14.2 13.5 14.0 14.46
PRESSURE
TO OBTAIN ins.wg. 5.1 , 4.2 5.5 5.8 52 5.7 5.42 5.8 5.9
HEAT INPUT 1 .

MAX INLET
mbar 20 20 20 20 I 20 20 20 20 20 .
PRESSURE ins.wg. 8 8 8 8 8 8 8 8 8

DATA SHEET MK III GAS SERIES BURNERS

HEATER MODEL 100 150 200 300 400 500 600 800 1000

BURNER GH G 1 G 1 G2 G2 G2 G3 G3 G3

mbar 3.7 4.9 6.1 4.9 6.1 7.2 6.8 6.9 ! 8.0
HEAD
PRESSURE ins.wg. 1.5 3.3
2.0 2.5 2.0 2.5 2.9 2.7 2.8

BURNER AIR SHUTTER N/A 2.0 2.8 1.0 3.0 5.0 1.0 3.0 3.0

BURNER GAS HEAD 2.0 2.0 1


2.8 0.0 3.0 4.0 0.0 7.0 7.0

kW 40 . 55 76 116 150 188 227 312 390


HEATER
INPUT Btux 10 3
138 186 1062 1331
253 397 513 643 773

kW 31 44 56 88 117 147 176 . 234 293


HEATER
OUTPUT 3
1000
Btux 10 112 150 202 300 400 500 600 800

GAS INLET 3/4 ' 1'12 "


'12 " V2' 3/ 4 " 3/ 4 1/ 1" 1" 1"
CONNECTION I

mm 125 125 150 150 175 175 200 250 250


FLUE SIZE
(NOMINAL) 10 10
ins. 5 5 6 6 7 7 8
I mbar 12.5 10.3 13.5 14.0 13.0 14.2 13.5 14.0 14.5
MIN. GAS I
INLET PRESS. ins.wg. 5.1 5.8 5.9
4.2 5.5 5.8 5.2 5.7 5.4

20 20
MAX. GAS I mbar 20 20 20 20 20 ' 20 20
INLET PRESS. 8 8
ins.wg. 8 8 8 8 8 8 8

Kg 208 208 407 407 496 511 550 707 780


WEIGHT
Ibs 458 458 1
897 897 1093 1127 1213 1559 1720
DATA SHEET MK III GAS MECTRON BURNERS

I HEATER MODEL 100 150 200 300 400 500 600 800 1000
I
BURNER GS 5 1 GS 5 GS10 GS10 GS 20 GS 20 GS 20 G3 G3

HEAD I mba r 2.50 3.75 1 2.50 4.25 1


2 .88 3.25 4.25 6.86 8.09
PRESSURE ins. wg. ; 1.0 1.7 2.8
1.5 1.0 1.7 1.15 1.3 3.3

BURNER AIR SHUTTER 2.0 3.6 2.5 4.0 3.6 4.5 5.5 7.0* 7.0*
I

BURNER GAS HEAD 1.8 3.0 3.0 4.0 2.5 3.5 3.9 3.0 3.0

kW 37 54 74 109 146 184 217 312 390


HEATER
INPUT Btux10 J
127 1062 1331
183 253 372 497 626 739
I
kW 30 43 , 61 87 119 148 176 234 293
HEATER 1
OUTPUT Btux 1O J 800 1000
103 148 208 297 405 504 599

GAS INLET 3/.' 3/4" 1"


I
1W'
V2" I '12" 3/4 /1 1" 1"
CONNECTION

mm 125 125 150 150 175 175 200 250 250


FLUE SIZE
(NOMINAL)
ins. 5 5 6 6 7 7 8 10 10

mbar < 12.0 < 12.0 < 12.0 13.5 < 12.0 12.0 14.5 14.0 14.5
MIN. GAS
INLET PRESS. ins.wg. 5.9
i < 5.0 5.0 < 5.0 5.5 < 5.0 5.0 6.0 5.8

mbar 20 20 100t 100t 100t 100t 100t 20 20


MAX. GAS
INLET PRESS. 8
ins.wg. 8 8 40 40 40 40 40 8

Kg 208 208 407 407 496 571 550 707 780


WEIGHT
Ibs 1
458 458 897 897 1093 1127 1213 1559 1720

*Internal setting. NOT shutter. t With CG Monobloc gas trains only. Standard gas train value 20mm (8").

7C ELECTRODE SETTINGS

Position of the ionisation probe Position of the ignition electrode


2+4mm

-+-+---'"-li- E
E
v
+
cry

IMPORTANT
Don't turn the ionisation probe, but leave it in the position as shown on the figure above; if moved towards
the ignition electrode the amplifier of the control-box could get damaged.

70 IONISATION CURREN.T
The minimum safe level of ionisation current to enable the control-box to operate correctly and detect a
gas-flame is 2 uA (two micro amps).
The control box will of course, under normal circumstances, never be required to operate under such a
small signal condition, by correctly positioning the flame electrode.
To test the ionisation current (and hence the flame signal strength) a direct current micro-ammeter should
be inserted in series with the flame electrode. as per diagram.
Ammeter

--------4c:
Cable
----+~BI-----4c: :3
Flame probe
7E COMBUSTION HEAD ADJUSTMENT - GAS 2 BURNER
Two separate adjustments have to be made. one for the air and one for the gas settings; these are carried
out when the firing head is still separate from the burner body, during installation.
Air setting
Loosen the screw (1), move the elbow (2) so that its rear (3) coincides with the chosen stop-gate number
on the graduate stop-plate scale.
Then tighten the screw (1) with a 6mm AUen Key.
Gas setting
Loosen the screw (5), and turn the ring nut (6) so that the pointer (7) coincides with the chosen stop-gate
number on the calibrated scale (8).
Then tighten the screw (5).

7F AIR PRESSURE SWITCH ADJUSTMENT


Adjust the setting of the air pressure switch after all other arrangements have taken place, starting from
the setting at the bottom of its scale.
While the burner is firing, increase the pressure by slowly turning the reglating knob clockwise, until the
solenoids close.
Then, turn the knob back by two turns and restart the burner, thereby checking that it functions regularly;
should another closing of the solenoids follow, turn back by one more full turn.
mbar

9
.,'- -
--;
.
5 I
•• 7 ] Adjustment­
:--, 3 range

Regulating­
knob

1 mbar = 1Omm w.g.

7G MOUNTING - GAS 3 BURNER

I
7H COMBUSTION HEAD ADJUSTMENT- GAS 3 BURNER
Two separate adjustments have to be made, one for the air and one for the gas; these are carried out

when the firing head is still separate from the burner body, during installation.

Air setting _

Loosen the two screws (1) and move the internal part of the firing head (2), so that its rear edge (3) is level

with the desired set-point on the plate (4). Then retighten the screws (1).

Gas setting

Loosen the screw (5), move the ring (6) so that the pointer (7) is level with the desired set-point (8). Then

tighten the screw (5).

8 6 5 2

7J SETTING INSTRUCTIONS FOR GRASSLIN TYPE SF SERIES TIME SWITCH


1. Access to the programme dial for time setting
To gain access to the programme dial for time seWng remove the Makrolon front cover by lifting off. This
exposes the 7 day programme dial and tappet slots on its rim into which the coloured tappets are inserted
to suit the switching programme.
2. Programme dial rotation
The programme dial is rotated by turning the top minute hand on the clock display in a clockwise
di'rection. During this operation a certain amount of noise is emitted from the gear movement as it is
rotated but this is normal and is in no way detrimental to the functioning of the control.
The main diall makes one revolution in 7 days with the markings in 24 hour clock system, though the clock
display is 12 hour system.
Important: Under no circumstances should the programme dial, be forced round in either direction as
damage to the gear assembly and switch will result.
Do not rotate programme dial by hand. Proglramme dial must be advanced by rotating minute hand
only.
3. Initial setting procedure
(a) Remove all tappets from the dial rim then commence the setting procedure by inserting a 'Green'
tappet embossed '1' into the slot at the required 'ON' time in the Monday segment on the dial, then a
'Red' tappet embossed '0' at the 'OFP time on that day noting that the 24 hour clock is used (6
rel'a tes to 6a.m. and 18 relates to 6p.m.). Minimum switching interval 3 hours.
(b) Repeat the operation in (a) for Tuesday, Wednesday etc. even though the 'ON' and 'OFP time may be
the same for each day.
(c) Where omission of any day or part is required it is only necessary to leave out completely the tappets
for that period as after operation of a 'Red' 'OFP tappet no switching will occur until the next 'Green'
'ON' tappet is operated.
(d) Check the tappet setting to ensure that 'Green' and 'Red' tappets alternate on the di,al and that a
'Green' tappet is always followed by a 'Red' tappet in a switching period. Spare tappets should be
placed in the parking holes provided.
(e) Adjust the time switch by rotating the minute hand on the clockface in a clockwise direction until
the correct day is opposite the .. on the dial located near the contact position indicator. FinalJ,y set
the clock hands to the correct time of day remembering the 24 hour telltale markilllg on each day on
the dial.
')P
4. Changing the programme
When introducing a change in the switching programme follow the initial setting procedure unless
repositioning of the tappets for a change can be effected so that instruction 3(d) stili applies, and that it is
for a day other than indicated by the arrow ...
5. Replace the Makrolon front cover ensuring that the notches on the cover locate in the slots in the
case.
6. The time switch is now ready for service.
7. Manual override
Turning the knob, located at one corner of the time switch, in an anti-clockwise direction, opens or closes
the switch contacts from '1' to '0' or '0' to '1' anticipating the next operation. This does not affect
subsequent switching programme, as already set.
WARNING: If difficulty is experienced in turning the manual override button, this will be due to the normal
operating tappets engaging with the override mechanism. Do not force under these conditions or
permanent damage may be caused. Wait for 15-20 minutes or advance the time by 15-20 minutes - see 2
and 3 above to allow the tappet to move from the position causing the problem.
Section Eight - Wiring Diagrams
THREE PHASE AIR HEATER WIRING DIAGRAM

For burner wiring refer


10 Burner Wifing D iagram
Terminal block
, Fan motor 400
In RieHo burner
Fan molor 500 I 49 amp 1
Fan molor 600 ! 6.5 amp I I 1 -1Fan ~L
-
I
Fan
Fan
molor 800
motor 1000
I
I
8.4
1 1.2
amp
amp
1

I
I stal
Umlt
stat

"I
''1
I
I
1~ 11 1 L Time J
IE I lw1
U V NJ IA I 1315
Conlactor
13 1}2 3 4 15 16 17 I
L
I-
OJ

'"
::: CF l

t-r-- W Room
slat

Supply
1 OIL relay

21
2 14
4
16 14 B . I " -
I6 96
...:
<ti
t:-- C
j--

It --

J
n '-
h 1::::
I

95

FrOSI
Sial
1- I

8~
.--
Summer
Fan l- f-
molor ~ f-Ft> OFF
r-- Winter

~~sitlon sWitch

SINGLE PHASE AIR HEATER WIRING DIAGRAM


Indirect drive
For burner wIfing refer
to Burner Wiring Diagram
OIL RELAY SETTINGS
Termmal block
Fan motor 400 in Riello burner
REFER
Fan motor 500
TO -',--­
I....--r-"T"""""T
Fan motor 600
MOTOR l 1 L
Fan motor 800 Fan limil
PLATE Slat stal
Fan motor 1000
I
n----~h
---1.....L..LJ'1

Contactor
t-
OJ
'":::
~c::Rl W Room

OIL relay
21416 14 B L~
rr--1L::--n '-hI slat

I
I
I-+-+-+--t-.....
J"--­ ~__~_______JI L ­_ _ _ _~
Supply 214[ 6 961----+-----i--+--++--------'
U 95

II I

8
'--!-­ .--­
Fan I-- '-----"""'f- Summer

motor ~I--_ _ ' - - - - - - - - - - - I f - Ft> OFF


r-- Wmter

~~sition sWItch
SINGLE PHASE AIR HEATER WIRING DIAGRAM
Direct drive-
--.J L r-
Fan Limit
stat stat
FAN MOTOR F.LA
Model
lOa
I
I
Amps
2.5
h r1
150 I 3.4
200 5.0
300 I 6.0

r t nn
IE ILINI4 1 5 6 17 18 1 91
~ ...-~
Frost I I I Room
sta.t 240,/·1 PH· 50Hz stat
:-l r supply
h r
I IL--_------.J 1
I [
J

...----+----1

;=f-­ I L..-:­
GS
Summer
an
motor j.-f--L.J- - - l
LI-f--.r--....... OFF
1 1 1 1
IL -nll '-------~n~ Winter Termina l bloc k

in Riello burner
3 Position SWitch For burner wiring refer
to Burner Wiring Diagram

THREE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL

For Ourner wiring reter


10 Burne r Wifing D iagram
O: L "IELAY SETTINGS
7ermlnal bloCk
Fan mo!or 400 ~ R,ello burner
F an mo 'or 500 4 9 amp

l I I
J w L r----
Fan mo,~r 600 I E 5 amp
Fan mOtor 800 I B4 amp Fan Limit
Fan mOtor t 000 I 112 amp s:al stat

""l I~

1~
rE ufvlw f N
I)
[A 11 315
Con:actor
I t3
l
1 t [2 3 41 51[ 6 '1 7 1
1Q)
<II
[AIS[CIOIE[r-
U .2
..:
1

="'
OI L relay
2 14 I6 t4 B ..J"-- -~
-
Supply ~ .I 4 !6 96
95

, .' •
GS~ I ,--
Fan l-
. Summer

motor ~ ~ft> OFF


Winter

G'p;;sltlon sWitch
SINGLE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL

Direct drive

FAN MOTOR F.LA.


Model Amps

100
2.5

150
3.4

200
5.0

300
6.0

Summer
OFF
Wmte r Terminal blOCM
in Riello burner
3 POsll lon SWIlch
For burner wIring refer
to Burner WIring Diagram

SINGLE PHASE HEATER WIRING DIAGRAM REMOTE CONTROL


Indirect drive

For burner wlrtng reter


10 Burner WIring Diagram

OIL RELAY SE!TINGS

Terminal bloCk

Fan motor 400


In Aiello bu rner
REFER
Fan motor 500
TO ~ ,
L f----
Fan motor 600
Fan motor 800
MOTOR
PLATE
I II .
I Fan
Sial I
Limit
sIal
Fan motor 1000

I
n L~

I II

1 IE
I
U I v Iw IN IA
n
I I 3 I 5 , '3
l
ItJ 2
,
31 4 I 5 11 617 j
IU
l ., I A IBI C ~D I EI
ContaClor '"
~
1
1 Supply
OI L relay

t 214161,t4
1 2 14 1 6 ~ 96
B I"--
<
.;
~

I
U [l5

(Sil-
B Fan
motor
I
O-

I--ft:>
I--
Summer
OFF
Winter
G'Pc;Sltlon sWIIch
COMMISSIONING CHECK LIST

Refer to 'Commissioning and Testing' Section Three of this Manual.

CHECK LIST Tick when completed

3B Control Chassis Inspection

f-­
3C I Time Switch Adjustment
3D I Room Thermostat Adjustment
3F I Fan Limit Thermostat settings
Explosion Relief Door Check
3G
I
3H I Fan Inspection and rotation check
31 I Flue pipe inspection

3J Combustion Air Supply Check


3K Gas Supply Check
3L Burner Inspection for air and gas settings
3M.3N
Gas Soundness Test
30 or 3P
3R Main Burner Gas Setting Pressure, mbar
State Pressure in mbar or ins. w.g. Ins. w.g.

3S Combustion Check
State percentage of Carbon Dioxide (C02) at flue outlet of heater I %
3T Set Air Pressure Switch
3U Flame Failure Lock-Out Check
3V All controls adjusted to suit customers requirements
3W Users Instructions handed over to Customer
Signature
Representative of I Date
Commissioning Organisation
Company

Leave this Commissioning Check List with user. Complete and despatch Warranty
Registration/Commissioning card and return to:

BENSON HEA TING LIMITED

LUDLOW ROAD,

KNIGHTON,

POWYS LD7 1 LP

TELEPHONE (0547) 528534

TELEX 35323

FAX 0547520399