Winterwarm TR Installation Manual Download

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No.

Description

TR10

TR15

TR20

TR24

TR28

TR40

TR50

Burner

IB3200

Ignition electrode

GA3400

Ignition cable

IY3949

Ionisation electrode

GA3402

Combustion fan

GA4500

GA4514

Gas valve

GA3394

System fan

IB4816

IX4201

IX4203

IH4206

Burner control unit
(EBM966)

GY5901

Pressure switch

IB3901

IB3900

IB3911

IB3900

IB3901

IB3902

Temperature sensor (heat
exchanger)

GY3934

Gasket set (TR)

GA6712

GA6714

Display board

GY5902

Delta-T sensor

GY3931

Rectifier block

GY3921

Fan relay

Flame insert (1 pc.)

GA6500

No.

Description

TR60

TR80

TR100

TR125

TR150

Burner

IB3204

Ignition electrode

GA3400

Ignition cable

IY3949

Ionisation electrode

GA3402

Combustion fan

GA4516

GA4517

Gas valve

GA3314

GA3319

System fan

IX4201

IX4203

IX4206

IX4207

Burner control unit
(EBM966)

GY5901

Pressure switch

IB3904

GA3968

GA3966

GA3964

Temperature sensor (heat
exchanger)

GY3934

Gasket set

GA6716

Display board

GY5902

Delta-T sensor

GY3931

Rectifier block

GY3921

Fan relay

IK5200

Flame insert (1 pc.)

GA6501

Summary of Contents for TR

Page 1: ...TR en v2 0 12 2019 INSTALLATION MANUAL AIR HEATER TYPE TR ...

Page 2: ...the flue terminal 16 6 Operating the air heater 18 6 1 Burner cycle 18 6 2 Minimum firing time 18 6 3 Delta T regulation 19 6 4 Summer ventilation 19 6 5 Overheating protection 19 6 6 Flue passage check 19 7 Commissioning the air heater 19 7 1 Adjusting the settings 19 7 2 Commissioning the air heater 19 8 Combustion settings 20 8 1 Adjusting the burner settings 20 8 2 Converting to another gas ty...

Page 3: ...anual DANGER Indicates a dangerous situation that would lead to death or severe injury WARNING Indicates a potentially dangerous situation that could lead to death severe injury or serious product damage CAUTION Indicates a potentially dangerous situation that could lead to injury or product damage NOTICE Indicates important information that is not directly related to safety 1 2 Warranty NOTICE Us...

Page 4: ...ining Chlorine that are sucked into the air intake will cause corrosion of the heat exchanger and a leakage of condensate and flue gas This is also the case for the room thermostat 2 2 Use CAUTION Make sure the area around the air heater is dry when performing maintenance on the air heater CAUTION Always close the doors and inspection hatches of the air heater except when adjusting and checking th...

Page 5: ...connection 50 Hz V 230 230 230 230 230 230 Electrical power consumption max kW 0 200 0 200 0 200 0 200 0 200 0 300 Electrical power consumption min kW 0 200 0 200 0 200 0 200 0 200 0 300 Stand by electrical power consumption kW 0 004 0 004 0 004 0 004 0 004 0 004 Electrical current A 1 4 1 4 1 4 1 1 1 1 1 3 Protection class IP00B Emission efficiency ηs flow 95 9 93 7 92 5 94 3 93 1 92 4 Seasonal s...

Page 6: ...230 Electrical power consumption max kW 0 425 0 350 0 600 0 750 1 100 1 500 Electrical power consumption min kW 0 425 0 350 0 600 0 750 1 100 1 500 Stand by electrical power consumption kW 0 004 0 004 0 004 0 004 0 004 0 004 Electrical current A 1 8 1 8 2 6 3 3 4 8 6 5 Protection class IP00B Emission efficiency ηs flow 93 6 93 4 94 0 93 4 93 7 93 5 Seasonal space heating efficiency 72 9 72 6 73 0 ...

Page 7: ...h 1 1 1 7 2 1 2 5 3 1 4 4 Burner injectors n x Ømm 2x 1 9 3x 1 9 4x 1 9 5x 1 9 6x 1 9 8x 1 9 Burner pressure high mbar 15 0 14 5 13 0 12 0 13 0 16 0 Burner pressure low mbar 10 5 11 5 7 0 8 5 9 0 11 0 CO2 High indication 8 0 8 2 8 0 8 0 8 0 9 0 Specification Unit TR50 TR60 TR80 TR100 TR125 TR150 Gas consumption max m3 h 5 4 6 9 8 6 11 2 14 0 16 1 Burner injectors n x Ømm 10x 1 9 5x 3 2 6x 3 7 8x 3...

Page 8: ...rner pressure low mbar 12 4 9 4 9 0 8 5 9 5 8 9 CO2 High indication 9 7 10 0 9 5 9 5 9 5 9 5 3 2 3 Butane Specification Unit Butane G30 B P Nominal supply pressure mbar 30 50 Supply pressure min max mbar 25 50 Gas category II2 H3 P B P NL II2 EK3 B P DE II2 ELL3 B P BE I3 B P FR II2 Er3 B P PL II2 ELwLs3 B P Class B23 C13 C33 Specification Unit TR10 TR15 TR20 TR24 TR28 TR40 Gas consumption max m3 ...

Page 9: ...0 1040 1040 1130 B mm 290 290 290 540 540 540 C mm 630 630 630 630 630 700 D mm 80 80 120 E mm 760 760 760 760 760 760 F mm 763 763 763 G mm 426 426 426 H mm 250 250 250 250 250 250 I mm 190 190 190 190 190 225 K mm 110 110 110 110 110 140 M mm Ø80 Ø80 Ø80 Ø80 Ø80 Ø100 N mm Ø80 Ø80 Ø80 Ø80 Ø80 Ø100 O mm 1 2 1 2 1 2 1 2 1 2 3 4 P mm 250 250 250 470 470 470 R mm 235 235 235 145 145 195 S mm 80 80 80...

Page 10: ...on the data badge Should there be any doubt about the settings that apply to your situation please contact your supplier 4 1 1 Standards NOTICE The installation must comply with all applicable local and national standards NOTICE The air heater must be installed in accordance with the relevant requirements of the Gas Safety regulations Electrical installation regulations and or other local regulati...

Page 11: ...80 TR150 Standard GA8675 TR10 until TR50 Turnable GA8670 can be rotated horizontally or forward Figure 5 Wall support standard Figure 6 Wall support turnable The air heater is equipped with threaded sockets to suspend the unit see 3 3 Use the suspension kit that is compatible with your air heater The suspension kit is not delivered with the air heater Contact your supplier 4 3 Gas type connection ...

Page 12: ...the electrical wiring diagram in 11 When replacing this fuse always use one of the same type 5AT 4 5 Room thermostat The heater can only be controlled with one of the following Winterwarm modulating room thermostats The MTS a modulating digital thermostat The MTC a modulating digital clock thermostat with optimiser Interface module a specially designed interface module for BMS systems Contact your...

Page 13: ... and J14 switches 4 5 3 Installation of multiple heaters on one control unit An MTC or MTS room thermostat or interface module can control up to 8 air heaters To connect the air heaters do the following figure 11 NOTICE This functionality does not apply to an ON OFF thermostat 1 Connect the two wires of the thermostat to termi nals 4 and 5 of the first air heater 2 Connect the first air heater to ...

Page 14: ... To ensure safe and proper use this air heater must be connected to a flue system This flue system must be installed according to this manual as well as national and local regulations A flue system consists of a flue terminal piping and an optional condensate discharge system CAUTION Do not use flue terminals for condensing appliances on non condensing heaters This can lead to water inside the flu...

Page 15: ...he connection between an air heater and the flue terminal cause a decrease in pressure Using a 90 bend decreases the maximum length of the connection by 2 meters Using a 45 bend decreases the maximum length of the connection by 1 meter For further information regarding the flue system please contact your supplier 5 3 Condensate in the flue system Condensate can form in the flue system when the air...

Page 16: ...ponents or materials from different manufacturers 5 4 1 Installation Roof terminal To install the flue terminal in the roof do the following 5 4 1 1 Preparation 1 Check all components for possible damage 2 Determine the roofing type Flat roof flashing Synthetic tile Universal pitched roof flashing 3 Determine where the flue terminal will be positioned 5 4 1 2 Installation 1 Create a hole from the ...

Page 17: ...ectly 5 4 3 Installation of the flue system parts This chapter gives the instructions for installing an ALU FIX flue system 5 4 3 1 Requirements The installation must follow these requirements Minimum distance between the flue system and combustible materials of 40 mm Minimum depth of female sockets of 40 mm Minimum slope of horizontal piping of 50 mm m 3 This allows condensate to flow to the heat...

Page 18: ...l or other obstacle 5 Fix the last element before entering the shaft in place If the last element is an elbow piece the next element must also be fixed in place 6 Check if ventilation openings and inspection hatches comply with national and local regulations 6 Operating the air heater 6 1 Burner cycle The air heater s display shows the current status of the burner cycle figure 19 Figure 19 Display...

Page 19: ...emperature the air heater performs the following actions Step 1 Power reduction when possible Step 2 Burner stop followed by an automatic restart when cooled down display E05 E36 Step 3 Burner stop followed by a Lock Out A manual reset is required display L15 NOTICE A manual reset can be done on the electronic circuit board or remotely with the special Room thermostat 6 6 Flue passage check The ai...

Page 20: ...re 2 Press the and buttons to toggle between Low and High fire figure 20 3 Press the button until 0 is displayed to exit the service The air heater will always cool down the heat exchanger for several minutes The test mode will automatically end after 10 minutes Figure 20 Using the display 8 Combustion settings In principle it is not necessary to adjust the control shortly after commissioning the ...

Page 21: ...dividual gas control valve 2 After the adjustment of the burner pressure check the burner pressure on each gas control valve Inlet Low setting High setting High Low Burner Figure 23 Main parts of the TR125 and TR150 gas valves 8 2 Converting to another gas type CAUTION For safety reasons the manufacturer recommends that the air heater is converted to another gas type only by the manufacturer its r...

Page 22: ...k outs The table below describes the volatile lock outs that can occur These can only be reset by hand Display Error type Description Case L 0 Internal error Internal error 13 L 1 Ignition error Flame lasts only 5 seconds after ignition 1 No flame after ignition 2 L 2 and 3 Internal error Internal error 13 L 4 E error E error for more than 24 hours 12 L 8 to 12 Internal error Internal error 13 L 1...

Page 23: ...lve Check if the ignition electrode sparks If not Check the cable and electrode and replace them when damaged Check the burner control unit and replace it when it does not give a spark output Case 3 Heat exchange sensor or flue sensor is overheated Check if the connectors J12 and J6 are plugged in correctly and if the connection J12 1 4 optional overheating protection is closed Check if the system...

Page 24: ...heater does start but shows a different problem than described above check if the following problems apply 9 5 1 Explosive ignition and or frequent flame failures Check if the gas control settings are correct see 8 1 A correct CO2 value is important for a proper ignition Check the ignition cable It should have a resistance of 1 kΩ Check the position of the ignition electrode The spark has to be fo...

Page 25: ...settings see 8 1 10 3 Maintenance of the burner unit The burner unit is an important part of the air heater and requires special maintenance To perform maintenance on the burner unit do the following 1 Disconnect the ignition and ionisation cables from the burner unit 2 Disconnect the burner manifold from the gas valve This is a clamp coupling 3 Remove the burner assembly from the air heater 4 Che...

Page 26: ...5 1 J5 2 J5 4 J5 3 4 3 1 2 J25 LED RESET 4 3 1 2 4 3 1 2 L on off 12 11 5 4 J17 N L N L Rect 7 6 N L 13 14 4 3 1 2 J16 4 3 1 2 A 24V B GND 20 GND 21 0 10V dP C2 C3 C4 C6 D1 D2 I3 M1 M4 S2 T1 T4 V2 I2 V2 K6 K6 11 13 Modbus L N P1 9 A1 10 A2 A1 8 N K6 PE A1 A2 RT No Connection type A1 Alarm output 230 V optional C2 Modbus connection C3 0 10 V input optional D1 Display 2 x 7 segment D2 Red and green ...

Page 27: ...K6 K6 11 13 Modbus L N P1 9 A1 10 A2 A1 8 N K6 PE A1 A2 RT No Connection type A1 Alarm output 230 V optional C2 Modbus connection optional C3 0 10 V input optional C4 Modulating thermostat C6 ON OFF thermostat optional D1 Display 2 x 7 segment D2 Red and green LED optional F1 Glass fuse 5 x 20 mm 5AT I2 Ignition electrode I3 Ionisation electrode K1 System fan relay K6 External reset optional M4 Co...

Page 28: ...he table below describes each part and shows the correct article number for a replacement part 7 7 18 19 20 10 11 5 16 6 13 17 8 15 14 12 1 23 21 22 4 2 3 9 24 25 30 Figure 28 Exploded view of the TR10 TR20 7 10 18 19 11 17 17 15 9 16 6 13 8 5 14 12 1 23 21 22 4 2 3 17 24 25 30 Figure 29 Exploded view of the TR24 TR50 ...

Page 29: ...AL AIR HEATER TYPE TR 7 20 18 11 17 5 15 16 9 6 13 8 10 17 14 12 1 23 21 22 4 2 3 24 25 26 30 Figure 30 Exploded view of the TR60 TR100 7 20 10 11 5 15 9 8 6 30 1 4 2 3 24 25 26 Figure 31 Exploded view of the TR125 TR150 ...

Page 30: ...ensor GY3931 GY3931 GY3931 GY3931 GY3931 GY3931 GY3931 25 Rectifier block GY3921 GY3921 GY3921 GY3921 GY3921 GY3921 GY3921 26 Fan relay 30 Flame insert 1 pc GA6500 GA6500 GA6500 GA6500 GA6500 GA6500 GA6500 No Description TR60 TR80 TR100 TR125 TR150 1 Burner IB3204 IB3204 IB3204 IB3204 IB3204 2 Ignition electrode GA3400 GA3400 GA3400 GA3400 GA3400 3 Ignition cable IY3949 IY3949 IY3949 IY3949 IY3949...

Page 31: ...t EU directives being 2016 426 EU GAR relating to appliances burning gaseous fuels 2014 35 EU LVD relating to the electric safety of appliances 2014 30 EU EMC relating to electromagnetic compatibility of appliances 2006 42 EG MD relating to the safety of machinery Goods should be installed and used in accordance with our instructions and with the applicable local and international rules Installati...

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