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SEELEY INTERNATIONAL AIRA DU SD Series, Installation And Operation Manual

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SEELEY INTERNATIONAL AIRA DU SD Series Installation And Operation Manual Download Page 23

DU/SD SERIES INSTALL OPERATION MAINTENANCE MANUAL  

|  

21

 

INSTALLATION INFORMATION

Figure 13: Gas Train Side View

 

AMI073-A

Figure 14: Gas Valve Supply View

 

ON/OFF 
Toggle  

AMI074-A

Burner 
Pressure 
Adjustment  

Figure 15: Gas Valve Discharge View

3.4.5 Gas Pressure Valve

Natural gas and LPG have different gas valves. The Natural gas valve may be identified by the on/off rotary knob where 

the LPG valve has a switch. Figures 14 and 15 depict a typical natural gas valve. Natural gas valves may be converted 

for use with LPG by using a conversion kit. Valves converted for use with LPG need to have appropriate stickers 

applied to the valve.

MANIFOLD

PILOT LINE

BALL VALVE

ON/OFF TOGGLE

SUPPLY GAS 

PRESSURE TEST 

POINT

PILOT 

PRESSURE 

ADJUSTMENT

3/4” GAS SUPPLY 

CONNECTION

BURNER 

PRESSURE 

ADJUSTMENT

PILOT 

CONNECTION

3/4” GAS SUPPLY 

TO MANIFOLD

REGULATED 

GAS PRESSURE 

TEST POINT

Summary of Contents for AIRA DU SD Series

Page 1: ...INSTALLATION AND OPERATION DU SD SERIES HEATER OR MODELS Original English Instructions AMI115 A ...

Page 2: ......

Page 3: ... 4 4 4 Modulating Motor Operational Check 27 4 5 Setting Controls 27 4 5 1 High Limit Control 27 4 5 2 Thermostat And User Controls 28 4 5 3 RLU Screens 28 4 6 Flow Adjustment Through Lever And Damper Blades 29 4 7 General Operation 30 4 8 Setting Unit Functional Parameters 31 4 9 Commissioning Results 31 OPERATING INSTRUCTIONS 5 1 Startup Wall Switch Units To Provide Heat 32 5 2 Startup Wall Swit...

Page 4: ...2 ...

Page 5: ...sues for those involved Installers are advised to ensure they are familiar with relevant State and Federal legislation such as Acts Regulations approved Codes of Practice and Australian Standards which offer practical guidance on these health and safety issues Compliance with these regulations will require appropriate work practices equipment training and qualification of workers Seeley Internatio...

Page 6: ...il the unit has been commissioned by qualified persons The unit should not be operated if any safeguards panels or controls have been removed damaged or bypassed If the unit is not operating as intended turn off the unit at the wall switch BMS and then isolate the power and gas supply The unit should remain isolated until a qualified service technician has inspected the unit and resolved any issue...

Page 7: ...er giving wet slippery surfaces Is there an on going safety check system of harnesses ropes ladders and access lifting equipment and where they exist on roofs anchor points before the commencement of work Is there a system which prevents employees from working on roofs if they are unwell or under the influence of drugs or alcohol Are there any special conditions to consider i e excessive roof pitc...

Page 8: ...e externally flued to atmosphere and in accordance with the Australian Standards and local regulations for flue installations of this type The units are natural draft and CAN NOT be installed in a negative pressure environment Commissioning can be provided by Seeley International otherwise for all type A appliances an experienced Type A installer is recommended Type B units will require independen...

Page 9: ... Type Optional Wall Switch Wall Switch Wall Switch Wall Switch Wall Switch Wall Switch Wall Switch Wall Switch Wall Switch Voltage V Ph Hz BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied BMS Customer Supplied FAN Type Blower Blower Blower Blower Blower Blower Blower Blowe...

Page 10: ...rd product range require pulley and belt combinations to be supplied by the customer All pulleys are of steel construction with taper lock mounting 2 4 6 Dampers All units are supplied with adjustable galvanised steel dampeners with preset positions to be set by the installer Axial fan units use the dampers to adjust air throw in addition to heat rise 2 4 7 Electrical Control and Connection All un...

Page 11: ...it shall also not be installed in a location that will affect the operation of mechanical devices used to displace air either within the same space or within a connected space DU SD units shall be installed so that adjacent combustible surfaces are protected from damage resulting from thermal effects of their operation If there are existing gas appliances the it shall be confirmed that there is ad...

Page 12: ... A FRONT C K L C B H A I J E C D 113 113 F B A 113 113 EQ EQ 111 2 111 2 113 113 B A B K H J C I F E A D C B C 112 EQ EQ 113 112 G DIM DU12 DU16 SD26 SD30 SD35 SD40 A 920 920 920 920 920 920 B 995 995 1556 1556 1890 1890 C 1253 1252 1570 1570 1918 1918 D 697 712 705 753 569 582 E Varies based on installation requirements F 510 510 728 728 987 987 G 457 596 865 1003 1208 1346 H 150 175 200 250 250 ...

Page 13: ...Q 112 4 112 4 A D E 113 113 F I J FRONT AMI139 A FRONT B C B G H C B A 113 113 EQ EQ 112 4 112 4 E 113 113 113 B A A D J I F E B G C B C 112 112 H EQ EQ 113 113 DIM DU12 DU16 SD26 SD30 SD35 SD40 A 1835 1835 1835 1835 1835 1835 B 995 995 1556 1556 1890 1890 C 1253 1252 1570 1570 1918 1918 D 697 712 705 753 569 582 E Varies based on installation requirements F 510 510 728 728 987 987 G 457 596 865 1...

Page 14: ...I140 A TOP AMI140 A REAR AMI140 A SIDE FRONT AMI140 A FRONT K A C A M L L B D G G K N N C H J J F I I E 3 1 3 UNIT DIMENSIONS DUAL HEAT EXCHANGER NO BLOWER DU SD DIM SD51 SD60 SD70 A 1025 1055 775 B 2730 2730 3135 C 1555 1555 1555 D 895 925 590 E Varies based on installation requirements F 630 630 630 G 800 935 1145 H 200 250 250 I 505 505 505 J 35 35 35 K 510 375 370 L 905 840 940 M 910 1045 1255...

Page 15: ...E M L I K G G K H C N I B A 55 49 49 49 50 50 55 J D I F B C L E M L I K G G K H C B N N I B A 55 49 49 49 50 50 55 N N B B L L M H K K G G C I I C E J J I F A D 55 55 49 49 49 50 50 AMI141 A ISO AMI141 A TOP AMI141 A REAR AMI141 A FRONT AMI141 A BOTTOM AMI141 A SIDE 3 1 4 UNIT DIMENSIONS DUAL HEAT EXCHANGER WITH BLOWER DU SD DIM SD51 SD60 SD70 A 1555 1555 1555 B 2730 2730 3135 C 1555 1555 1555 D ...

Page 16: ...When selecting a location for the DU SD unit the following shall be considered 1 Will the unit be suitably protected from the effects of corrosion and or dust laden environments and any likelihood of physical damage 2 Can qualified personnel perform functional adjustments and maintenance on the unit 3 Does the chosen location prevent a hazard to the building or structure or to the contents of the ...

Page 17: ...ocate unit in an enclosed plant room unless sufficient openings are available to ensure air pressure in the plant room CANNOT become negative with all items in the plant room operating Mechanical ventilation may be required Failure to achieve positive plant room pressure will result in gas combustion gasses being drawn into the room being heated presenting a health risk to any occupant A suitably ...

Page 18: ...41 A Figure 6 Securing Example 3 2 5 Lifting Units are to be lifted by the points specified and designed to lift only the specific units dry weight These lifting points are suitable for either Crane or Helicopter lift with suitable spreader bars The unit cabinet is lightweight aluminium and at no point should the lifting slings or spreader bar contact the cabinet failure to comply will permanently...

Page 19: ...f a different flue design is used the flue up draft must be confirmed after appliance if started to ensure adequate flow Flue temperatures are expected between 250 to 300 Deg C and may require additional flue skins especially when penetration through walls roofs floors etc Figure 7 Duct Connections Figure 8 Flue Connections 3 2 7 Duct Connections The outlet of the unit is provided with a 40mm flan...

Page 20: ...agram package and should be used in conjunction with this manual Electrical circuit breakers must be a minimum of a D curve motor start circuit breaker Electrical circuit breakers must be sized according to the total load requirements For Weatherproof units the electrical connection will require a hole saw to drill through a corner panel for conduit entry When entering the unit DO NOT run cables o...

Page 21: ...al heat exchangers The unit will be supplied with two thermostats The room thermostat measures temperature in the room the set point thermostat allows for adjustment of the set temperature Both thermostats are to be installed within the area being heated 3 4 GAS CONNECTIONS 3 4 1 Gas Supply This unit must be installed in accordance with AS NZS 5601 1 Before connecting the unit to the gas line The ...

Page 22: ...n affect the combustion process within the unit causing light back and poor combustion leading to excessive emissions 3 4 3 Gas Supply for Dual Heat Exchangers Dual heat exchanger units have 2 independent gas valves and control systems therefore require 2 separate gas supply connections Each gas supply requires an isolation valve and shall be individually commissioned Pipework to the unit shall be...

Page 23: ...ay be identified by the on off rotary knob where the LPG valve has a switch Figures 14 and 15 depict a typical natural gas valve Natural gas valves may be converted for use with LPG by using a conversion kit Valves converted for use with LPG need to have appropriate stickers applied to the valve MANIFOLD PILOT LINE BALL VALVE ON OFF TOGGLE SUPPLY GAS PRESSURE TEST POINT PILOT PRESSURE ADJUSTMENT 3...

Page 24: ...regulated valve pressure is to be set based of the ranges in Table 11 To set the regulated pressure follow the steps below 1 Connect a manometer to the supply pressure test point 2 Measure the incoming gas pressure to ensure that it less than 3 5kPa If found to be greater than 3 5kPa the gas valve may be in a locked state A pressure regulator will need to be installed upstream of the gas valve to ...

Page 25: ...Low fire may be adjusted by limiting the travel of the modulating valve utilizing adjusting screw 9 to ensure the gas cuts off before the rate is reduced too far A rate equal to 59 of full gas rate may be obtained by adjusting the gas flow at the low fire setting which equates to the correct minimum gas flow rate NG Full Gas 870kPa Low Gas 300kPa LPG Full Gas 2 5kPa Low Gas 875kPa Correct adjustme...

Page 26: ...ion Ensure that the pilot is secured in position with both screw and the injector clip 3 4 10 Aeration Plates All Gas trains require an Aeration Plate installed to achieve proper primary aeration Ensure that the Aeration plate is installed fully in a fully closed position with minimal gaps between the manifold and aeration plate If the unit experiences light back issues ensure that the aeration pl...

Page 27: ... in good condition and free from damage 3 Check that the unit is sufficiently secured and level If located on a roof stand ensure that the roof stand is installed as per the designing engineers specifications 4 Check that ductwork from the unit is correctly installed and secured by a qualified person 5 Flue installed and secure 6 Check that all pads are in position and free of foreign material 4 3...

Page 28: ...me will enter the adjacent main burner gas stream Refer to Pilot Injector Setup Section 6 Purge all air from the pipeline and check for leaks by using a soap solution or leak detector 7 Check gas supply pressure before gas valve Must be less than 3 5 kPa Gas pressures exceeding 3 5Kpa will cause the units gas valve to lockup requiring relief of the line pressure prior to the valve This is generall...

Page 29: ...ed at full open 5 Reduce the room set temperature just below the current room temperature This operation causes the unit to reduce the gas rate as the set temperature reaches the room temp 6 The modulating motor should begin to modulate the burner pressure down to the set low gas rate 7 The unit should then switch off the main burner and pilot 4 5 SETTING CONTROLS 4 5 1 High Limit Control All unit...

Page 30: ...f the valve is positioned less than 10 the burner will turn off If the Position is greater than 20 the burner will turn on The room set temperature is indicated by the RH value As the room thermostat set value is altered the value will change accordingly The LH value is the current room temperature as room thermostat The RLU has an upper limit setting of 29 Deg C The leaving air temperature sensor...

Page 31: ...n handle located beside the control box on the duct outlet which will lock the blades in one of three positions Full Open 1 2 Open and Fully Closed Temperature rise across Heat Exchanger needs to be 11 C to 33 C Dampers should be fully open for initial testing and gradually closed to achieve the required temperature rise COMMISSIONING INFORMATION Figure 25 Dampers Full Open AMI089 A Figure 27 Damp...

Page 32: ...inlet of unit stop cock If inlet pressure is less than minimum specified on the label either gas supply line to the unit is under sized and or restricted or the meter outlet pressure is too low WARNING If the gas pressure is lower than specified it may result in burner light back potentially causing damage to the burners and increased soot buildup in the heat exchanger and flue Contact the local g...

Page 33: ...odulating motor controls the temperature or the leaving air temperature reaches 40 C causing the unit to shut down Examples are provided in Appendix E Table 9 Temperature Rise Over Heat Exchanger provides a starting point for airflows over the heat exchanger to achieve the desired temperature rise Model ΔT 11 C ΔT 28 C DU12 2098 L s 840L s DU16 2800 L s 1118 L s SD26 4460 L s 1784 L s SD30 5240 L ...

Page 34: ... the Heat switch to OFF 5 4 SHUTDOWN WALL SWITCH UNITS PROVIDING VENTILATION 1 Switch the wall switch ON OFF switch to OFF 2 Switch the Fan Switch to OFF 5 5 BMS STARTUP AND SHUTDOWN It is the responsibility of the BMS installer to provide instruction and training on the operation of the interface Note 1 BMS wiring should be done in accordance with Aira Manual AM006 No changes should be made to th...

Page 35: ... Sense detects pilot 30 seconds break Gas valve releases supply to main burner Adjust thermo stat to desired temperature 4 minutes Reset system adjusts supply to main burner Temperature in room the set temperature Unit goes into standby Temperature in the room decreases Switch off Unit at Wall Switch Gas valve closes sup ply to main burner and pilot allowing unit to cool Fan Stops Unit adjusts supp...

Page 36: ...hedule A detailed service schedule and Maintenance checklist can be found in Appendix D Appendix D also contains a monthly checklist for the owner Component Minimum Inspection and Service Schedule Belts Quarterly visual inspection 6 monthly thorough inspection Pulleys Quarterly visual inspection 6 monthly thorough inspection Heater Maintenance Every 6 Months Motor In accordance with manufacturers ...

Page 37: ... and a digital thermometer heat the overtemp control switch until the switch activates 4 Turn off unit The fan should continue to run until the overtemp control switch reaches 32 5 Refit the overtemp control switch The following are the recommended steps for removing the overtemp control switches 1 Turn OFF main isolator and follow LOTO procedures Failure to do so may result in Injury or Death 2 D...

Page 38: ...red from steel or aluminium and will generally require replacement less than the drive belts Any wear on the pulleys will shorten the drive belt life therefore should be replaced if there are any signs of wear Tools Required Metric open end ring spanner set Drive belt tensioning gauge Pry bar or lever bar Socket set metric hex key set nylon hammer 1 Electrically isolate unit 2 Remove Blower Box ac...

Page 39: ...ove pilot burner assembly 3 Remove burner tubes one at a time by sliding bars sufficiently towards the front of the heater against the spring resistance to disengage the rear end of the burner tube from the manifold plate lower end of burner tube and remove from front location plate 4 CLEANING MAIN BURNER BARS Lightly brush away any deposit from the burner bars and inspect for damage or blocked po...

Page 40: ...work connection into the unit for damage When the unit is operating inspect the ductwork for leaks where visible 6 2 3 3 General Installation Visually inspect the mounting and how the unit is secured to the roof ground Ensure that the unit is stable and correctly aligned with the ductwork 6 2 3 4 Access to Unit Check that access to the unit is free of obstructions If the unit is located on a roof ...

Page 41: ... stuck in open position 3 Gas valve defective stuck in close position 1 See wiring diagram check for electrical supply at valve terminals in junction box with test lamp or Multimeter 2 Bridge across limit switch terminals If burners light replace switch 3 Replace gas valve Unit Overheats and Locks Out on Limit Switch 1 Gas valve stuck in open position 2 Inadequate air delivery from blower 3 Poor a...

Page 42: ...r cross light bars not positioned correctly 1 Remove and clean 2 Remove and clean 3 Realign Pilot to Burner 4 As per Commissioning 5 Remove burners and align Burners do not light 1 Exceed 3 5kPa inlet causing gas valve to lock 1 Isolate Gas Supply 2 Remove inlet gas fitting to depressurize valve 3 Reduce Gas pressure at regulator to below 3 5kPa 4 Reconnect gas supply and test at test point Table ...

Page 43: ...DU SD SERIES INSTALL OPERATION MAINTENANCE MANUAL 41 APPENDIX A AGA TYPE B INFORMATION Contact Seeley International for further details ...

Page 44: ...42 Please refer to AM006 Aira Control Configuration Options DU SD WD CH637 DU SD HCV Control Box Wiring Diagrams APPENDIX B ELECTRICAL INFORMATION ...

Page 45: ... 1 1 1 1 1 1 1 1 6 PU009 UNION BARREL GAL BS 3 4 F F 1 1 1 1 1 1 1 1 7 PB419 BEND GAL M F 1 1 1 1 1 1 1 1 8 PP238 PRESSURE TEST POINT 1 8 G09 3 3 3 3 3 3 3 3 9 648613 PIPE MEDIUM GAL mm 160 240 320 400 480 560 680 760 10 PE071 ELBOW GAL F F 1 1 1 1 1 1 1 1 11 PZ643 1 8NPT X NUT OLIVE 1 1 1 1 1 1 1 1 12 PT032 TUBE ALUMINIMUM 6 35mmODX1 42 330 410 490 570 650 730 850 930 13 PB773 PILOT INJECTOR NG 0...

Page 46: ...PM307 14 PG149 REGULATOR MAXITROL RV12 1 8 Optional 1 1 1 1 1 1 1 1 15 PC394 LPG CONVERSION KIT WHITE ROGER 1 1 1 1 1 1 1 1 Gas Train On Off Natural Gas Item Number Part Number Description DU10 DU12 DU16 SD22 SD26 SD30 1 PC332 WR GAS VALVE 24V 36C68C 1 1 1 1 1 1 2 648613 PIPE MEDIUM GAL mm 150 150 150 150 150 150 3 PN037 NIPPLE GAL HEX 1 1 1 1 1 1 4 PU009 UNION BARREL GAL BS 3 4 F F 1 1 1 1 1 1 5 ...

Page 47: ...Fitted Gas Supply free of condensate and deposits Gas Train Connections Pilot Connection Incoming Line Purge Incoming Gas Pressure kPa Gas Valve Converted for LPG Correct Spuds Installed and Free of Obstructions Visual Inspection of pipe work with leak detector Modulating Motor Set and Operational Check Controls High Limit Control securely installed and free of damage High Limit Temp as specified ...

Page 48: ...ONING REPORT Electrical Commissioners Details Name Date License number Signature Gas Commissioners Details Name Date License number Signature Water Commissioners Details Name Date License number Signature Commissioning Notes ...

Page 49: ...ampers need to be opened further to allow for greater airflow across the heat exchanger APPENDIX E2 SET TEMPERATURE CANNOT BE REACHED HCV12 with an airflow of 2098 L s over the heat exchanger to achieve a 11 C rise in temperature The outside air temperature is 15 C Thermostat is set to 29 C The airflow over the heat exchanger is too high to allow for the temperature to increase sufficiently to hea...

Page 50: ... rise 22 C rise in temperature The outside air temperature is 15 C Thermostat is set to 29 C The leaving air temperature sensor does not exceed 40 C so the unit continues to operate As the room temperature reaches the set temperature of 29 C the modulating motor begins to modulate the gas flow to maintain a steady temperature If the modulation does not lower the temperature sufficiently the unit w...

Page 51: ...rational Fan Motor Belts Pulleys Visual Inspection Belts Pulleys Thorough Inspection Fan Obstructions Direction Damper Operation Gas Incoming Gas Supply Gas Connections Visual Inspection Gas Isolation Fitted and in Good Condition Gas Supply Pressure Gas Burner Pressure High Low Gas Injectors Draft Diverter Pilot Assembly Burner Operation and Combustion Flue Operation Leaving Air Sensor Installatio...

Page 52: ... Casing Access to unit Access to unit is clear of obstructions Weatherproof casing Case is secure not damaged and Maintenance records Previous maintenance records are in a safe location and any required maintenance items have been actioned ONLY A QUALIFIED TECHNICIAN SHALL ADJUST SETTINGS Checked By ______________________________ Signature ________________________________ Date _________________ AP...

Page 53: ...ions and direction Check fan is clear of any foreign objects Confirm fan is operating in correct direction Damper Operation Check temperature rise across the heat exchanger Check that dampers are locked in correct position Gas Incoming Gas Supply Visually inspect incoming gas connection for signs of damage Check that the site gas shut off valve is in good working condition and easily accessible If...

Page 54: ... level Maintenance records Check that previous maintenance records are in a safe location and any required maintenance items have been actioned Operation Start up and run sequence Check that unit operates as expected with no visual sound or smell abnormalities Control Operations Check that thermostat and wall switch BMS controls operate as expected Motor Amps High and Low Speed Check motor amps on...

Page 55: ...________ Model _________________________________________________________ Serial No _________________________________________________________ Customer Name _________________________________________________________ Installation Address ______________________________________________________ Date of Installation _______________________________________________________ Installer Dealer _________________...

Page 56: ...e Goods 4 We are under no obligation to repair or replace the Goods or Parts under clause 1 above if i the Goods have not been installed and commissioned in accordance with the Installation Instructions ii the Goods have not been installed and commissioned properly or competently iii the Goods have not been operated serviced and maintained in accordance with the instructions provided in the Owner ...

Page 57: ...al Health and Safety requirements and by laws which are legislated or in effect at the time of installation 11 This warranty is only valid and enforceable in Australia Note It is important that the safety and privacy of our service technicians is protected at all times Accordingly We and our Seeley International service agents reserve the right to refuse service if i safety and accessibility to th...

Page 58: ...ort We may also disclose your information to third parties such as related entities retailers distributors service agents and contractors who are affiliated with us or marketing or market research companies If you would prefer not to receive direct marketing communications from us please follow the instructions to unsubscribe which will be included in the direct marketing communications we send yo...

Page 59: ...mendment Author Approved 1 0 A 04 06 2021 Initial Release D Wall C Arnel 1 1 B 12 08 2021 SD30 Type A update D Wall C Arnel 1 2 C 27 09 2021 Tabel and Dimension update D Wall C Arnel 1 3 D 25 01 2022 SD26 and SD40 Type A update D Wall C Arnel APPENDIX H RELEASE INFORMATION ...

Page 60: ...dealer to confirm the specifications of the model selected MANUFACTURED BY SEELEY INTERNATIONAL PTY LTD 77 NORTH ST ALBURY NSW 2640 AUSTRALIA SEELEY INTERNATIONAL TECHNICAL SUPPORT 1300 650 399 AUSTRALIA 0800 589 151 NEW ZEALAND SEELEY SPARE PARTS DISTRIBUTORS 1300 367 437 AUTHORISED SERVICE AGENTS 1300 650 644 Service All regions other than Australia Please contact your local distributor seeleyin...

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