Mandik HELIOS Installation, Operation Instructions And Maintenance Manual Download Page 1 | Manualshive

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Summary of Contents for HELIOS

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Page 2: ... Installation of the exhaust box 23 13 Gas connection installation 24 14 Electrical installation 24 15 Adjustment procedure adjustment values 25 16 Operating Instructions 31 17 Maintenance 32 18 Failure of infrared heaters HELIOS and their removal 32 19 Conversion to another type of fuel 34 20 Components used in infrared heaters HELIOS 35 21 Control box 35 22 Wiring diagram 37 23 Economizer functi...

Page 3: ...of floors walls machines and other objects are heated by radiation and the surrounding air is heated from them The infrared heater HELIOS consists of the following main parts with hinges and the radiant heating tubes U or I The basic design of the burner box is scalded by the throat for the external suction in the upper part of the burner box If the combustion air supply system is not connected it...

Page 4: ...wo stage Infrared heater with single stage burner works in on off mode two stage burner of the infrared heater operates in off mode reduced power full power The main advantages of the two stage burner control include reducing burner start up frequency better temperature distribution in the heated space and reduced energy consumption nfrared radiators HELIOS are divided in terms of installation and...

Page 5: ... INOX 1580 mm E Black tube 4595 mm 1 socket F Black tube 3090 mm 1 socket H Black tube 3290 mm 1 socket I Black tube 4595 mm 2 sockets K Black tube 3090 mm 2 sockets O Wire eye for spinners V Spinner Burner box HS Exhaust box OS Socket tube joint with clamp V O V H E I A A K F V O V H V O V H I B HELIOS 40 I HELIOS 30 I HELIOS 20 I ...

Page 6: ... B Stainless steel tube INOX 1580 mm E Black tube 4595 mm 1 socket F Black tube 3090 mm 1 socket G Black tube 1585 mm 1 socket I Black tube 4595 mm 2 sockets K Black tube 3090 mm 2 sockets O Wire eye for spinners V Spinner Burner box HS Exhaust box OS Socket tube joint with clamp HELIOS 40 U HELIOS 30 U HELIOS 20 U HELIOS 10 U ...

Page 7: ...k tube 4595 mm 1 socket F Black tube 3090 mm 1 socket G Black tube 1585 mm 1 socket I Black tube 4595 mm 2 sockets K Black tube 3090 mm 2 sockets O Wire eye for spinners V Spinner Burner box HS Exhaust box OS Socket tube joint with clamp 3 5 1 3 3 2 1 1 1 1 4 4 4 4 2 2 2 3 3 3 3 3 3 5 5 5 K F F C E K E A A B E I F F V V O I F V V O F V V O F E V V O V O HELIOS 50 LU HELIOS 40 LU HELIOS 30 LU HELIO...

Page 8: ...wo places by using an appropriate way so that the device cannot be turned around 3 Due to the thermal expansion the infrared heater can not be fixed directly to the supporting structure 4 It is necessary to keep safe distance from flammable objects and walls Fig 9 10 When installing the heater over the runway of bridge crane it is necessary to use the protection of electrical power installation of...

Page 9: ...ording to relevant standards Opening for flue gases measurement is placed according to heater configuration for heaters without economizer the opening is in the first part of the duct immediately after the heater for heaters with economizer the opening is in the first part of the flue duct immediately after the economizer For pressure losses of individual flue system components see following table...

Page 10: ...20 8 9 5 DN 100 4 6 8 11 16 102 112 14 16 8 DN 125 3 4 6 6 11 35 35 10 11 6 DN 125 4 6 9 10 16 51 51 15 16 9 1 Helios heater 2 Tube with throat 3 Exhaust head horizontal 1 2 3 2 1 2 3 4 3 6 7 3 5 4 2 1 HELIOS heater 2 Condensate trap 3 Tube with throat 4 Bend 5 Join female female 6 Exhaust head horizontal 7 Air intake head ...

Page 11: ...5 2 1 3 3 5 2 3 4 1 HELIOS heater 2 Condensate trap 3 Tube with throat 4 Flexible duct Al 5 Coaxial chimney vertical 1 HELIOS heater 2 Condensate trap 3 Tube with throat 4 Exhaust head vertical 5 Air intake head ...

Page 12: ...uilding The appliance is classified according to the flue into design version A The design and installa tion of the flue gas exhaust must comply according the correct norm When installing the heater in design A in enclosed space it is necessary to ensure forced ventilation with min 10 m h for each installed kW power consumption of the heater in design A and it is necessary to ensure that the devic...

Page 13: ...5 4 24 8 31 3 14 0 26 7 28 9 15 4 24 8 31 3 230 50 100 4 17 26 28 50 1 26 2 07 2 07 3 43 3 43 4 25 4 25 1 30 2 15 2 15 3 55 3 55 4 40 4 40 0 91 1 51 1 51 2 48 2 48 3 09 3 09 1 82 3 01 3 74 2 07 3 43 4 25 1 33 2 18 2 72 3 0 4 0 5 0 5 5 1 9 2 6 3 3 3 8 10 9 5 9 5 10 10 10 5 10 5 13 0 13 13 13 13 13 5 13 5 27 0 25 25 23 23 21 21 7 5 8 0 8 2 9 5 10 0 10 5 19 0 18 5 16 5 3 8 5 3 6 8 8 3 0 009 0 015 0 0...

Page 14: ...38 4 14 1 23 5 29 2 36 1 15 5 25 5 31 3 38 4 230 50 100 4 17 26 28 50 2 07 2 07 3 43 3 43 4 25 4 25 5 14 5 14 2 15 2 15 3 55 3 55 4 40 4 40 5 32 5 32 1 51 1 51 2 48 2 48 3 09 3 09 3 60 3 60 1 82 3 02 3 74 4 52 2 07 3 43 4 27 4 70 1 33 2 18 2 72 3 30 4 0 5 0 5 5 6 2 2 6 3 3 3 8 4 2 9 5 9 5 10 10 10 5 10 5 10 5 10 5 13 13 13 13 13 5 13 5 13 5 13 5 25 25 23 23 21 21 17 17 7 5 8 0 8 2 8 2 9 5 10 0 10 ...

Page 15: ...g the combustion air from outside Closed appliance is strongly recommended The installation must comply with applicable standards and regulations and with this installation manual Infrared heaters cannot be installed in places where there is a risk of fire or explosion or high levels of flammable dust Infrared heaters HELIOS can be used for heating in public areas where this type of heating is per...

Page 16: ...ctor holders mounted on the hinge see Fig 31 32 34 35 1 1 Radiant tube black 3 Hinge U type 5 2 Clamp 4 Arch 102 180 4 3 2 1 Radiant tube black 3 Hinge U type 5 5 Tube INOX 2 Clamp 4 Arch 102 180 6 Radiant tube black 2 sockets 1 4 3 2 2 5 6 3 2 4 1 2 1 Tube INOX 3 Radiant tube black 2 sockets 2 Clamp 4 Radiant tube black 3290 mm 1 Insert the tube into the throat so that the holes in the tube and i...

Page 17: ...oller without plate 1 Strap 2 Washer 6 4 4 Nut M6 4 5 4 1 1 6 4 1 Radiant tube 102x2 black 3 Washer 6 4 6 Strap 102 2 Nut M6 4 Hanging point 7 Hinge U 2 3 Hinge U type 1 with hole for roller without plate 1 Expansion insert 1 Roller 1 Strap 1 Supporting rod 2 Washer 6 4 6 Nut M6 6 2 4 5 6 7 8 5 9 1 7 10 1 Radiant tube 102x2 black 3 Washer 6 4 5 Supporting rod 7 Hanging point 9 Strap 102 2 Nut M6 4...

Page 18: ...e the expansion insert on the hinge 7 Protection tube for ca ble connecting 2 Nut M6 4 Hanging point 6 Strap 102 8 Hinge I with expan sion insert 1 4 7 6 5 8 4 3 2 2 1 Radiant tube 102x2 black 3 Washer 6 4 5 Supporting rod 7 Hanging point 9 Strap 102 11 Hinge U with expansion insert roller and plate 2 Nut M6 4 Roller 6 Place the expansion insert on the hinge 8 Radiant tube INOX 10 Plate 2 3 6 5 7 ...

Page 19: ...and plate 7 4 8 1 4 9 6 5 3 2 2 Hinge I type 2 with plate 1 Strap 1 Washer 6 4 2 Nut M6 2 1 Radiant tube 102x2 black 3 Washer 6 4 5 Plate 7 Protection tube for cable connecting 2 Nut M6 4 Hanging point 6 Strap U 6 8 Hinge U with expansion insert and plate 5 7 4 1 8 4 6 3 2 2 Hinge I type 1 without plate 1 Strap 1 Washer 6 4 2 Nut M6 2 1 Radiant tube 102x2 black 3 Washer 6 4 5 Strap 102 7 Hinge I 2...

Page 20: ...xpansion insert 9 Reflector clap 2 Bolt M6 4 Hanging point 6 Strap 102 8 Additional Hinge U 15 3 8 6 1 4 1 5 7 4 2 9 1 Radiant tube 102x2 black 3 Washer 6 4 Nut M6 5 Roller 16 7 Reflector U 15 9 Radiant tube 102x2 INOX 11 Supporting rod 13 Reflector clap 2 Nut M6 4 Hanging point 6 Strap 102 8 Hinge U with expansion insert 10 Supporting rod with fin 12 Bolt M6 14 Additional hinge U 15 1 4 o 8 6 10 ...

Page 21: ...4 1 Radiant tube black 3 Washer 6 4 Nut M6 5 Reflector I 15 7 Hinge I 9 Protection tube for cable connecting 2 Reflector clap 4 Hanging point 6 Strap 102 8 Additional Hinge I 15 9 4 1 5 7 4 6 8 3 2 1 Hinge U 15 3 Washer 6 4 5 Insulated reflector U 15 7 Holder of the insulated reflector 2 Bolt M6x12 4 Nut M6 6 Frond washer 6 4 3 2 7 6 4 5 1 ...

Page 22: ...ith chains or strings hanging rods etc Lift the infra red heater to the proper height level and ensure that it is hung in horizontal position Always make sure that the fasteners have sufficient load capacity Placing of the gas spinners Gas spinners in heaters Helios I are placed in the last heating tube in front of the exhaust box Gas spinners in heaters Helios U are placed immediately behind the ...

Page 23: ... GBS clamp over the socket like when connecting radiant pipes and tighten it firmly The recommended torque is 25 Nm Connect the burner and the exhaust box with the supplied cable which in the I version is guided by an armored tube placed in the hinges Tube 102x2 GBS Clamp Pull the socket of burner box over the pipe to stop and lock it with GBS clamp GBS Clamp Burner box In the same way as the burn...

Page 24: ...ct the hoses from mechanical stresses and aggressive media The hoses must not be subjected to any tension Dimension G is G1 2 for Helios 10 to 40 G3 4 for Helios 50 Burner box Gas hose Gas connection Ball valve Place the box of remote control according to the project so that it is freely accessible for the servicing staff Connection of the box for remote control to the main supply distribution of ...

Page 25: ...h the heaters are connected Main guard valve of gas must be opened the gas distribution must be vented and adequate gas overpressure must be assured We recommend presence of a person acting on behalf of assembling company and on behalf of a user for the purpose of training the operation staff 1 Check the conformity of assembly of heater flue gases exhaust and Air intake duct visually with this man...

Page 26: ...y 10 mm wrench in order to prevent its movement For the direction of screw turning in order to rise or decrease jet pressure see fig 43 4 Switch the heater to minimum power by removing the dual cable marked with the letter C in figure 43 and check the jet pressure if necessary for minimum power according to the table for the type of radiator and the procedure above 5 Switch the heater to rated pow...

Page 27: ... 88 5 89 0 88 0 89 0 90 2 91 0 90 1 90 6 G20 7 5 19 0 G20 7 5 19 0 G25 9 5 G25 9 5 17 5 17 5 17 5 17 5 Natural gas Propane G31 Natural gas Propane G31 Natural gas Propane G31 4 0 2 6 4 0 2 6 4 0 2 6 G20 9 5 25 0 G20 9 5 25 0 G20 9 5 25 0 G25 13 0 G25 13 0 G25 13 0 G20 19 5 19 9 G20 19 9 19 9 G20 19 9 19 9 G25 18 5 G25 18 5 G25 18 5 143 148 145 150 145 150 150 155 110 120 115 120 8 5 9 3 8 9 9 2 8 ...

Page 28: ... 0 94 5 95 5 96 5 97 5 95 0 96 0 G20 7 5 19 0 G20 7 5 19 0 G25 9 5 G25 9 5 17 5 17 5 17 5 17 5 Natural gas Propane G31 Natural gas Propane G31 Natural gas Propane G31 5 0 3 3 5 0 3 3 5 0 3 3 G20 11 5 23 0 G20 10 0 23 0 G20 10 0 23 0 G25 14 0 G25 13 0 G25 13 0 G20 36 5 33 0 G20 33 0 33 0 G20 33 0 33 0 G25 33 9 G25 30 7 G25 30 7 190 200 185 195 225 240 225 240 200 215 195 210 6 0 6 5 8 8 9 1 6 0 6 5...

Page 29: ...1 5 92 5 91 0 92 0 93 2 94 0 93 0 93 8 G20 8 0 18 5 G20 8 0 18 5 G25 10 0 G25 10 0 29 0 26 8 29 0 26 8 Natural gas Propane G31 Natural gas Propane G31 Natural gas Propane G31 5 0 3 3 5 0 3 3 5 0 3 3 G20 11 5 23 0 G20 10 0 23 0 G20 10 0 23 0 G25 14 0 G25 13 0 G25 13 0 G20 36 5 33 0 G20 33 0 33 0 G20 33 0 33 0 G25 33 9 G25 30 7 G25 30 7 126 131 143 150 151 158 156 163 126 131 143 150 6 0 6 5 9 0 9 3...

Page 30: ... 7 9 7 8 8 1 8 6 8 3 7 8 8 4 91 0 91 2 91 0 91 2 88 0 89 5 87 5 89 0 91 0 91 3 91 0 91 3 91 0 91 5 91 0 91 2 G20 8 2 16 5 G20 8 2 16 5 G20 8 2 14 5 G25 10 5 G25 10 5 G25 10 5 36 0 36 1 36 0 36 1 43 6 43 5 Natural gas Propane G31 Natural gas Propane G31 Natural gas Propane G31 5 5 3 8 5 5 3 8 5 5 3 8 G20 10 5 21 0 G20 10 5 21 0 G20 10 5 21 0 G25 13 5 G25 13 5 G25 13 5 G20 41 0 41 0 G20 41 0 41 0 G2...

Page 31: ...position 1 2 Turn the switch STOP to the position or in this case the infra heater operation is performed under the automatic mode which it is necessary to program according to the relevant control box instructions The green indicator of the electric supply lights up on the control box also green indicator on the bottom of burner box will light on 3 After finishing the ventilation time app 50 s th...

Page 32: ...ty of control box Visual inspection of all electric insulations of the appliance their exchange if needed ventilator does not work no reaction to the release Defective ventilator Replace the ventilator Defective automatics Replace the automatics Faulty electric connection of the burner box Check the connection exhaust box Defective air manostat Replace the air manostat Defect in the burner box ele...

Page 33: ...R SUPPLY the red lamp for ERROR and orange lamp OPERATION Also the connectors for burner box and exhaust box and control panel connection are mounted on the shell 1 Disconnect the burner box and the electric supply by removing the large connector X1 X1 and close the gas supply 2 Disassembly the upper case and the cover 4x stud bolt 3 Disassembly the electrode holder 2x screw and nut M4 4 Disconnec...

Page 34: ...smantling is difficult That is why it is advised to exchange the whole burner with jet Together with new burner a self adhesive label Conversion shall be supplied which has to be filled in and stuck next to the product data label 2 Disconnect the burner box and the electric supply by removing both connectors close the gas supply and disconnect from the gas distribution 3 Disconnect the burner box ...

Page 35: ...ge heaters is manual OID enables automatic and manual control of one OID 1 to six OID 6 one stage or two stage tube heaters HELIOS The control box has IP 40 rating The control box is equipped with UC301 IP 20 regulator with time programme The load selection of two stage heaters automatic The UC301 is a communication two stage regulator for gas heaters with SSR outputs It can work autonomously or b...

Page 36: ...ng If the above placement is not possible suitable temperature correction has to be added to the programmed temperatures T2S3 N L1Pe COMNO N L Pe L1 L1 N NT1 T1 T2 T2S3 S3 Power supply 230V 50Hz Power supply 230V 50Hz Power supply 230V 50Hz Note Sensor is connected according investors requirement JYTY 2x1 shielded max distance 30m JYTY 7x1 max distance 10m ...

Page 37: ...tor 230 V 50 Hz Protective conductor N Neutral conductor T1 Signalization of error output 230 V T2 Signalization of operation output 230 V S3 Two stage level input 230 V 1 Wire CYA 0 75 black 2 CMSM 3c x 0 75 3 Wire CYA 0 75 blue 5 Wire CYA 0 75 green yellow 6 VN silicon cable CFG 4T2 12 dia 3 1 L1 Signallizatin of operation L2 Signallizatin of failure L3 Signalization of power supply PA Gas armat...

Page 38: ...ith 2 m length of heat exchanger AWTM 100 4000 with 4 m length of heat exchanger AWTM 125 4000 with 4 m length of heat exchanger Economizer is placed in flue system immediately after the tube heater Electric supply of the fan can be from connector on the burner box or by cable from mains 230V 50Hz When the heater is started the flue gases flow inside the internal heat transfer surface and heat it ...

Page 39: ...ure of 20 C L N PE TP 45 C VENT PE N CMSM 3C x 0 75 KR 2 L Length mm 2000 3950 4087 Weight kg 14 5 26 47 Power supply V Hz 230 50 Electric input W 50 75 Air flow m3 h 600 750 Thermal output with HELIOS 10 420 W 950 W Thermal output with HELIOS 20 690 W 1200 W Thermal output with HELIOS 30 1400 W 1720 W Thermal output with HELIOS 40 1900 W 2350 W Thermal output with HELIOS 50 2300 W Available press...

Page 40: ...ely after economiser there must be condensate trap with condensate output and output of flue gases out of the building 1 HELIOS tube heater 3 Condensate trap flue gas es measurement here 5 Roof discharge head 2 Economizer AWTM 4 Flue duct 6 Condensate outout connection G3 4 Min Slope 2 2 1 5 4 3 6 The producer reserves the right for innovations of the product For actual product information see www...

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