Post on 03-May-2020
ECONOAIR 3000S SERIES AIR HANDLING UNIT
DIRECT FIRED
Installation Operation amp Maintenance Instructions
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
TABLE OF CONTENTS 30008
1 TECHNICAL DATA 5
11 Specification 5 12 Utilities 6 13 Settings (As shipped) 7
Process and Instrumentation Diagram
General Arrangement
Wiring Diagram
2 GENERAL DESCRIPTION8
21 Introduction 8 22 Gas Burner Assembly 8
23 Control System 8 231 Safety Controls 8
232 Temperature Control System 9
233 Main Control PaneL 9
234 Fuel Gas System 9
235 Remote Control Station 10 236 HEATED SPACE TEMPERATURE SENSOR 10
3 INST ALLA-rION 11
31 Statutory Requirements 11 32 Reception and Storage of Goods 11
321 Reception 11 322 Off Loading 11 323 Storage 11
33 Limitations of Use 12 34 Location of Air handlers 12 35 Fresh Air Inlet and Ventilation 13
351 Fresh Air Inlet 13 352 Ventilation 14
36 Air Discharge 14 37 Recirculation Air Entry 14 38 Remote Station 15 39 Visual Check 15 310 Connection of Services 15
3101 Fuel Gas Supply 15 3102 Electricity Supply 16
311 Connection to the Main Panel and Remote Station 16 312 Heated Space Temperature Sensor 16 313 Duct Sensor 16 314 Overheat Limit Control Sensor 16 315 Touch Screen Wiring 17
JULY 1999 SAMPLE Page 1
TABLE OF CONTENTS 30008
316 Alignment 18 3161 Installation Of Drive Belts 18 3162 Pulleys 18
3163 Alignment 18
3164 Belts 18
3165 Installation and Take Up Allowance 19
4 COMMISSIONING 20
41 Pre-start Checks 20 42 Dry Run 21 43 Start Up 21
431 Flame Signal Check 22 432 Handover 22
5 ADJUSTMENTS 23
51 Pilot Adjustment 23
52 Burner High Fire Pressure Adjustment 23
53 Burner Low Fire Adjustment 23
54 SUMMERIOFFIWINTER Switch 24 55 RESET Button 24
6 OPERATING INSTRUCTIONS 25
61 Air handler Start-up 25 62 Air handler Shut-down 25
621 Shutdown For Short Periods 25
622 Shutdown For Prolonged Periods 25 63 General Instructions 26
631 Site Clearance Adjacent to Air handler 26 632 Air Supply to Air handler 26 633 Air Filters 26
634 Service 26
635 Spare Parts 26 636 Gas Leaks 26
7 FAULT FINDING 27
71 POWER ON light is unlit 27 72 AIR FAN ON light is unlit 28 73 2LOCKOUT light is illuminated 29
75 AIR FAN ON light is illuminated 29
JULY 1999 SAMPLE Page 2
TABLE OF CONTENTS 30008
8 SERVICING 30
81 Isolation 30 811 Fuel Gas Isolation 30 812 Electrical Isolation 30
82 Routine Maintenance 31
83 Annual Service Checks 31
84 Removal Procedure For Replaceable Components 32 841 Burner 32
842 Flame Detector 32 843 Igniter Spark Plug 32 844 Igniter Spark Transformer 33 845 Combustion Air Pressure Switch (DPS) 33 846 Air handler Overheat Limit ControL 33 847 Air Fan and Motor 33
848 Fuel Gas Multi-functional Control - Small Units 34 849 Governor and Block Valves 34 8410 Fuel Gas Flow Control Valve 34 8411 Pilot Gas Governor and Block Valve 34 8412 Belt Tensioning Procedure 35
85 Main Panel Controls 37 851 Landis amp Gyr LFL 1335 Automatic Sequence Controller 37
852 Controls Circuit (24 Volt) Transformer 37 853 Controls Relays R1 R2 amp R3 37 854 6A MCB 37 855 Thermal Overload 37 856 Main Contactor 38 857 Motor Fuse 38
86 Remote Control Station 38
9 RECOMMENDED SPARES 39
JULY 1999 SAMPLE Page 3
TABLE OF CONTENTS 30008
APPENDIX 1
SOUNDNESS TESTING THE FUEL GAS LINE 40 A11 Testing the Upstream Pipework and Burner Controls 40 A12 Testing the Downstream Burner Valve 41 A13 Testing the Downstream Burner Pipework 41 A14 Testing the Downstream Pilot Pipework 41 A15 Testing the Burner Connections 42
APPENDIX 2
START SEQUENCE 43
APPENDIX 3
SERVICE CHECK SHEET 47
APPENDIX 4
TEMPERATURE CONTROLLER ~ 48 A41 Time Out Screen 48 A42 Status Screen 49 A43 Changing Settings 50 A44 Entering the Security Code 50 A45 Changing or Setting a Time Schedule 52 A46 Changing Set Values 54 A47 Commissioning and Servicing Burner Checks 55
A48 GMTltgtBST Changeover (Daylight Saving) 55
JULY 1999 SAMPLE Page 4
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
TABLE OF CONTENTS 30008
1 TECHNICAL DATA 5
11 Specification 5 12 Utilities 6 13 Settings (As shipped) 7
Process and Instrumentation Diagram
General Arrangement
Wiring Diagram
2 GENERAL DESCRIPTION8
21 Introduction 8 22 Gas Burner Assembly 8
23 Control System 8 231 Safety Controls 8
232 Temperature Control System 9
233 Main Control PaneL 9
234 Fuel Gas System 9
235 Remote Control Station 10 236 HEATED SPACE TEMPERATURE SENSOR 10
3 INST ALLA-rION 11
31 Statutory Requirements 11 32 Reception and Storage of Goods 11
321 Reception 11 322 Off Loading 11 323 Storage 11
33 Limitations of Use 12 34 Location of Air handlers 12 35 Fresh Air Inlet and Ventilation 13
351 Fresh Air Inlet 13 352 Ventilation 14
36 Air Discharge 14 37 Recirculation Air Entry 14 38 Remote Station 15 39 Visual Check 15 310 Connection of Services 15
3101 Fuel Gas Supply 15 3102 Electricity Supply 16
311 Connection to the Main Panel and Remote Station 16 312 Heated Space Temperature Sensor 16 313 Duct Sensor 16 314 Overheat Limit Control Sensor 16 315 Touch Screen Wiring 17
JULY 1999 SAMPLE Page 1
TABLE OF CONTENTS 30008
316 Alignment 18 3161 Installation Of Drive Belts 18 3162 Pulleys 18
3163 Alignment 18
3164 Belts 18
3165 Installation and Take Up Allowance 19
4 COMMISSIONING 20
41 Pre-start Checks 20 42 Dry Run 21 43 Start Up 21
431 Flame Signal Check 22 432 Handover 22
5 ADJUSTMENTS 23
51 Pilot Adjustment 23
52 Burner High Fire Pressure Adjustment 23
53 Burner Low Fire Adjustment 23
54 SUMMERIOFFIWINTER Switch 24 55 RESET Button 24
6 OPERATING INSTRUCTIONS 25
61 Air handler Start-up 25 62 Air handler Shut-down 25
621 Shutdown For Short Periods 25
622 Shutdown For Prolonged Periods 25 63 General Instructions 26
631 Site Clearance Adjacent to Air handler 26 632 Air Supply to Air handler 26 633 Air Filters 26
634 Service 26
635 Spare Parts 26 636 Gas Leaks 26
7 FAULT FINDING 27
71 POWER ON light is unlit 27 72 AIR FAN ON light is unlit 28 73 2LOCKOUT light is illuminated 29
75 AIR FAN ON light is illuminated 29
JULY 1999 SAMPLE Page 2
TABLE OF CONTENTS 30008
8 SERVICING 30
81 Isolation 30 811 Fuel Gas Isolation 30 812 Electrical Isolation 30
82 Routine Maintenance 31
83 Annual Service Checks 31
84 Removal Procedure For Replaceable Components 32 841 Burner 32
842 Flame Detector 32 843 Igniter Spark Plug 32 844 Igniter Spark Transformer 33 845 Combustion Air Pressure Switch (DPS) 33 846 Air handler Overheat Limit ControL 33 847 Air Fan and Motor 33
848 Fuel Gas Multi-functional Control - Small Units 34 849 Governor and Block Valves 34 8410 Fuel Gas Flow Control Valve 34 8411 Pilot Gas Governor and Block Valve 34 8412 Belt Tensioning Procedure 35
85 Main Panel Controls 37 851 Landis amp Gyr LFL 1335 Automatic Sequence Controller 37
852 Controls Circuit (24 Volt) Transformer 37 853 Controls Relays R1 R2 amp R3 37 854 6A MCB 37 855 Thermal Overload 37 856 Main Contactor 38 857 Motor Fuse 38
86 Remote Control Station 38
9 RECOMMENDED SPARES 39
JULY 1999 SAMPLE Page 3
TABLE OF CONTENTS 30008
APPENDIX 1
SOUNDNESS TESTING THE FUEL GAS LINE 40 A11 Testing the Upstream Pipework and Burner Controls 40 A12 Testing the Downstream Burner Valve 41 A13 Testing the Downstream Burner Pipework 41 A14 Testing the Downstream Pilot Pipework 41 A15 Testing the Burner Connections 42
APPENDIX 2
START SEQUENCE 43
APPENDIX 3
SERVICE CHECK SHEET 47
APPENDIX 4
TEMPERATURE CONTROLLER ~ 48 A41 Time Out Screen 48 A42 Status Screen 49 A43 Changing Settings 50 A44 Entering the Security Code 50 A45 Changing or Setting a Time Schedule 52 A46 Changing Set Values 54 A47 Commissioning and Servicing Burner Checks 55
A48 GMTltgtBST Changeover (Daylight Saving) 55
JULY 1999 SAMPLE Page 4
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
TABLE OF CONTENTS 30008
316 Alignment 18 3161 Installation Of Drive Belts 18 3162 Pulleys 18
3163 Alignment 18
3164 Belts 18
3165 Installation and Take Up Allowance 19
4 COMMISSIONING 20
41 Pre-start Checks 20 42 Dry Run 21 43 Start Up 21
431 Flame Signal Check 22 432 Handover 22
5 ADJUSTMENTS 23
51 Pilot Adjustment 23
52 Burner High Fire Pressure Adjustment 23
53 Burner Low Fire Adjustment 23
54 SUMMERIOFFIWINTER Switch 24 55 RESET Button 24
6 OPERATING INSTRUCTIONS 25
61 Air handler Start-up 25 62 Air handler Shut-down 25
621 Shutdown For Short Periods 25
622 Shutdown For Prolonged Periods 25 63 General Instructions 26
631 Site Clearance Adjacent to Air handler 26 632 Air Supply to Air handler 26 633 Air Filters 26
634 Service 26
635 Spare Parts 26 636 Gas Leaks 26
7 FAULT FINDING 27
71 POWER ON light is unlit 27 72 AIR FAN ON light is unlit 28 73 2LOCKOUT light is illuminated 29
75 AIR FAN ON light is illuminated 29
JULY 1999 SAMPLE Page 2
TABLE OF CONTENTS 30008
8 SERVICING 30
81 Isolation 30 811 Fuel Gas Isolation 30 812 Electrical Isolation 30
82 Routine Maintenance 31
83 Annual Service Checks 31
84 Removal Procedure For Replaceable Components 32 841 Burner 32
842 Flame Detector 32 843 Igniter Spark Plug 32 844 Igniter Spark Transformer 33 845 Combustion Air Pressure Switch (DPS) 33 846 Air handler Overheat Limit ControL 33 847 Air Fan and Motor 33
848 Fuel Gas Multi-functional Control - Small Units 34 849 Governor and Block Valves 34 8410 Fuel Gas Flow Control Valve 34 8411 Pilot Gas Governor and Block Valve 34 8412 Belt Tensioning Procedure 35
85 Main Panel Controls 37 851 Landis amp Gyr LFL 1335 Automatic Sequence Controller 37
852 Controls Circuit (24 Volt) Transformer 37 853 Controls Relays R1 R2 amp R3 37 854 6A MCB 37 855 Thermal Overload 37 856 Main Contactor 38 857 Motor Fuse 38
86 Remote Control Station 38
9 RECOMMENDED SPARES 39
JULY 1999 SAMPLE Page 3
TABLE OF CONTENTS 30008
APPENDIX 1
SOUNDNESS TESTING THE FUEL GAS LINE 40 A11 Testing the Upstream Pipework and Burner Controls 40 A12 Testing the Downstream Burner Valve 41 A13 Testing the Downstream Burner Pipework 41 A14 Testing the Downstream Pilot Pipework 41 A15 Testing the Burner Connections 42
APPENDIX 2
START SEQUENCE 43
APPENDIX 3
SERVICE CHECK SHEET 47
APPENDIX 4
TEMPERATURE CONTROLLER ~ 48 A41 Time Out Screen 48 A42 Status Screen 49 A43 Changing Settings 50 A44 Entering the Security Code 50 A45 Changing or Setting a Time Schedule 52 A46 Changing Set Values 54 A47 Commissioning and Servicing Burner Checks 55
A48 GMTltgtBST Changeover (Daylight Saving) 55
JULY 1999 SAMPLE Page 4
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
TABLE OF CONTENTS 30008
8 SERVICING 30
81 Isolation 30 811 Fuel Gas Isolation 30 812 Electrical Isolation 30
82 Routine Maintenance 31
83 Annual Service Checks 31
84 Removal Procedure For Replaceable Components 32 841 Burner 32
842 Flame Detector 32 843 Igniter Spark Plug 32 844 Igniter Spark Transformer 33 845 Combustion Air Pressure Switch (DPS) 33 846 Air handler Overheat Limit ControL 33 847 Air Fan and Motor 33
848 Fuel Gas Multi-functional Control - Small Units 34 849 Governor and Block Valves 34 8410 Fuel Gas Flow Control Valve 34 8411 Pilot Gas Governor and Block Valve 34 8412 Belt Tensioning Procedure 35
85 Main Panel Controls 37 851 Landis amp Gyr LFL 1335 Automatic Sequence Controller 37
852 Controls Circuit (24 Volt) Transformer 37 853 Controls Relays R1 R2 amp R3 37 854 6A MCB 37 855 Thermal Overload 37 856 Main Contactor 38 857 Motor Fuse 38
86 Remote Control Station 38
9 RECOMMENDED SPARES 39
JULY 1999 SAMPLE Page 3
TABLE OF CONTENTS 30008
APPENDIX 1
SOUNDNESS TESTING THE FUEL GAS LINE 40 A11 Testing the Upstream Pipework and Burner Controls 40 A12 Testing the Downstream Burner Valve 41 A13 Testing the Downstream Burner Pipework 41 A14 Testing the Downstream Pilot Pipework 41 A15 Testing the Burner Connections 42
APPENDIX 2
START SEQUENCE 43
APPENDIX 3
SERVICE CHECK SHEET 47
APPENDIX 4
TEMPERATURE CONTROLLER ~ 48 A41 Time Out Screen 48 A42 Status Screen 49 A43 Changing Settings 50 A44 Entering the Security Code 50 A45 Changing or Setting a Time Schedule 52 A46 Changing Set Values 54 A47 Commissioning and Servicing Burner Checks 55
A48 GMTltgtBST Changeover (Daylight Saving) 55
JULY 1999 SAMPLE Page 4
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
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COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
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ORAtO 023739
PILOT LINE
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Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
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o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
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I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
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GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
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IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
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Serial No
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SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
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lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
TABLE OF CONTENTS 30008
APPENDIX 1
SOUNDNESS TESTING THE FUEL GAS LINE 40 A11 Testing the Upstream Pipework and Burner Controls 40 A12 Testing the Downstream Burner Valve 41 A13 Testing the Downstream Burner Pipework 41 A14 Testing the Downstream Pilot Pipework 41 A15 Testing the Burner Connections 42
APPENDIX 2
START SEQUENCE 43
APPENDIX 3
SERVICE CHECK SHEET 47
APPENDIX 4
TEMPERATURE CONTROLLER ~ 48 A41 Time Out Screen 48 A42 Status Screen 49 A43 Changing Settings 50 A44 Entering the Security Code 50 A45 Changing or Setting a Time Schedule 52 A46 Changing Set Values 54 A47 Commissioning and Servicing Burner Checks 55
A48 GMTltgtBST Changeover (Daylight Saving) 55
JULY 1999 SAMPLE Page 4
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
1 TECHNICAL DATA 30008
SPECIFICATION
308 99shy
CE 0087
G20 87AQ371
NA
17
10
5
415V 50Hz 3ph 4 Wire
A
kg
IE
JULY 1999 SAMPLE PageS
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
1 TECHNICAL DATA 30008
UTILITIES
AIR HANDLER UTILITIES
FUELi NATURAL GAS
MAXIMUM FUEL SUPPL Y PRESSURE 25 mbar
MINIMUM FUEL SUPPL Y PRESSURE 15 mbar
ELECTRIC SUPPL Y TO CONTROL PANEL WITH NEUTRAL WIRE
415V 50Hz 3ph 4 Wire
SUPPLY RATING Amps
MOTOR FUSES
Notes
Air handler models 3018S to 3040S inclusive of STOKVIS ECONO-AIR 3000S Series air handlers have been certificated by British Gas Pic for use on Natural Gas only It does not cover the use of distribution ducting filters and high level or external installations The other air handlers in the range are designed and built to the same parameters and standards as the certificated sample
Your attention is drawn to the limitations on location for recirculation air handlers detailed in Section 33
JULY 1999 SAMPLE Page 6
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
1 TECHNICAL DATA 30008
SETTINGS (AS SHIPPED)
AIR HANDLER SETriNGS (AS SHIPPED) I
I
IAIR PRESSURE SWITCH rnbar
OVERHEAT LIMIT CONTROL 65degC
PILOT BURNER GAS PRESSURE 100 mbar
MAXIMUM 50 mbar MAIN BURNER GAS PRESSURES
MINIMUM 10 mbar
MAXIMUM AT RECIRCULATION CONDITION NA
OVERLOAD Amps
FAN SPEED rpm
MAXIMUM 16 mbarDIFFERENTIAL AIR PRESSURE ACROSS PROFILE PLATE MINIMUM 14 mbar
GAS CONNECTION SIZE BSP
TEMPERATURE CONTROLLER
ACCESS CODE 4321 I
TEMPERATURE SETPOINT (Code 00) 19degC i
SAMPLE INTERVAL (Code 01) 2 sec I
DISCHARGE LOW LIMIT (Code 02) 18degC
DISCHARGE HIGH LIMIT (Code 03) 36degC
Note For air handler dimensions please refer to the General Arrangement Drawing
JULY 1999 SAMPLE Page 7
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
~------------------~--~
~~O~~C~~~__-__~~middot~~I~~______________-1~~~__~~-=~~=-~i
COMPONENT UST
BURNER
AIR FAN MOTOR
FAN DRIVE
CONTROL PANEL
REMOTE PANEL
SERVICES
FUEL
UAX SUPPLY PRESSURE MIN SUPPLY PRESSURE
ELECTRICITY
BLOCK VALVES
Serial No
bullbull IlICh NPII
kW 1+4ORPM
NA
3-30005-100 RevO DOL Start
N
NATURAL GAS
25mbor 1gtmbor
15V5OHz3Ph4W1RE Motor FLC bullbullbull Amps
240V 50Hz 1Ph 3 WIRE
Site Address
TAG DESCRIPTION WI SUPPLY ISOlATION VALve
W2 JW3 MULTIBLOCKMY MV5 FLOW CONTROL VALve WS BURNER ISOLATION VALVE
PVl PILOT PRESSURE REGULATOR PV2 PILOT SOlpoundNOIO VALve PV3 PILOT ISOlATION VALve
TC SPACE lEMPERATURE CONTROUER TO DISCHARGE TEMPERATURE DETECTOR TR SPACE TEMPERATURE DElECTOR TS OISCHARGE TEMPERATURE swrrCH
PS AIR PRESSURE swrrCH
UV fLAt4E DETECTOR
t SPARK IGNITER
NOTE f INIlICATES PRpoundSSURE TEST POM
Client
srOKVIS END USERS ADDRESS END USER
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN
Ident T45
shyomiddot BVIoI 0 145
1 DJSO 1 GBlA 14 T45
1AC600 00T1701 DRT3453 RAK13bullbull170
lWGJ
ORAtO 023739
PILOT LINE
fRtsH Nfl HET
Title TITLE
Model No Seri4l No DutY Style
Tel 0181 941 1212 Fax 0181 941 4136
00lCIIAAGE 10 WORIltSPAtt
305 99- m3sINDOOR HORIZONTAL
ACStw -_nora I-ID_raw_-+I__-I
Checked
CONTROL Approved
o-1 CommentApproval
Rev IDote I Description
Computer No 99
Purchase Order No
Drawing No
4-MR-001 R~O~
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
~_ON
lOCKOUT
s
o Rev I Dote I Description
Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
o
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
NOTES1shy
I PROPOSED LOCATION TO BE CHECKED tOR LEVEL AND LOAD BEARING STRENGTH BY OTHERS
2 UNIT TO BE SUPPLIED IN SEPERATE SECTIONS FOR LIFTING INTO PLANTROOM AND ON TO BASE BY OTHERS
3 ALL SECTIONS TO HAVE TIJO BEADS OF SEALANT BETJEEN OPPOSING FLANGES AS PER SUPPLIED INSTALL ATlON INSTRUCTIONS
ltI ENSURE ALL BUILDERS JORK IS CARRIED OUT AND MADE GOOD AFTER INSTALLATION BY OTHERS
5 ALL EXTERNAL JIRING SHALL BE CARRIED OUT BY COMPETENT PERSON TO CURRENT lEE REGULATIONS
DISCHARGE OPENING lUOlElIE VIDE X lIE HIG CV 3011 MEZ FLANGE
Serial No
sroKVIS Site Address Client END USERS ADDRESS END USER
ACCESS OPENING
~L---gt lt0-shy
~ ~
GAS CONNECTIONS
CONTROL PANEL 60011 VIDE X 600111 HIGH
APPROX VEIGHTSshy
HEATER CASING - 1I0U( KG
IJCL OOCUUef IDrawn lACS
Checked
I RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 fax 0181 941 4136 CONTROL IApproved
o I~ I CommentApproval
Rev IDate IDescription
Computer No
99 Purchase Order No
Drawing No
3-MR-005
415VOlT5OHz 4 WIRE sumy
lIfEI_-shy~a
30131
2_F11
3 TOO---shy
B (
Serial No
~s
~~~~
~ NIt 9lOIElIliOTt)R RA11NG~W
STOKVIS
0 reg
-0
0 0 lt0
u ~
R5-1 -
ADDRESS
shy
regshy
~tl
GAS v IoIOtQR AIIIfONGTll LEGEND
IHlmN PNEI _
-e- PNEl_
Sl1pound_
-11shy IJIfClIOII1IO~-
DUCT STAT NPE COt 17tll
_STAT NPE om 3lt4Il)
~~~pound~ niR~~ (i)l
~ ()1
_cbullbullL~ nmiddoti Apoundm
USER
~ ~
SCHEMATIC FOR 3000S SERIES AIR
IAC600 BASED
RS STOKVIS amp SONS Ltd POOL ROAD WEST MOLESEY SURREY KT8 2HN Tel 0181 941 1212 Fax 0181 941 4136
_[---------f P(N(J ON
ICHI11ONTfWiSFORlER
PllOT V IIEIi CAS VAllIE 1
II CAS VAllIE 2
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Computer No 99
Purchase Order No
Drawing No
3-MR-100 Rev
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30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
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30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
30005 2 GENERAL DESCRIPTION
21 INTRODUCTION
The STOKVIS ECONO-AIR 3000S Series air handler is a direct fired unit designed to give clean healthy environmental conditions and constant even temperature within the heated space
The main air handler assembly houses the circulating air fan the gas burner the fuel gas line and all necessary safety controls The burner management system and space temperature controller is located in the main control panel mounted on or adjacent to the side of the air handler A second control station supplied loose for mounting remote from the air handler within the heated space or other convenient location houses indicating lights the control touch screen and auxiliary operational switches
A sight glass is fitted on the air handler casing to view the burner during operation
For multi unit networked applications the touch screen is excluded
22 GAS BURNER ASSEMBLY
The ECONO-AIR 3000S Series air handler incorporates the Maxon NP-II burner This burner is specially designed for heating fresh air and is mounted such that a proportion of the incoming air is forced into contact with the flame to ensure rapid mixing and combustion within the code requirements The burner assembly is built up from modular components to give the required heat duty
Each burner assembly is fitted with an integral pilot spark igniter and UV detector The flame detector is used for scanning both the pilot and main flame Note that the pilot burner operates in interrupted mode
The burner module fitted is identified in the Technical Data Section of this manual and on the Valve and Instrun1ent list
23 CONTROL SYSTEM
The controls fitted on the air handler are detailed on the Process amp Instrumentation Diagram in the Technical Data Section of this manual
231 SAFETY CONTROLS
The safety interlocks on the ECONO-AIR 3000S Series air handler are
1 Combustion air proving switch (PS) 2 Ultra-violet burner flame detector (UV) 3 Overheat limit control (OLe)
Failure of either the combustion air switch or fiame scanning circuit will cause the air handler to go to LOCKOUT and the burner management system will require a RESET before a re-light can be attempted
The air handler discharge overheat limit control is a manual reset switch After a failure the switch will have to be RESET before a re-light can be attempted
JULY 1999 SAMPLE Page 8
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
2 GENERAL DESCRIPTION 3000S
232 TEMPERATURE CONTROL SYSTEM
The ECONO-AIR 30008 Series air handler is fitted with a full three-term modulating temperature control system as standard The space temperature is sensed by a heated space detector (TR) which inputs to the panel mounted temperature controller (TC) This achieves control by modulation of the fuel gas flow control valve (MV5) The temperature controller additionally limits the air handler discharge air temperature measured by the discharge temperature detector (TO) to pre-set high and low limits
233 MAIN CONTROL PANEL
The control panel houses the combustioncirculation air fan starter the burner management system and the heated space temperature controller On larger units a separate starter panel may be supplied The panel door is fitted with an interlocked isolator POWER ON and LOCKOUT lights and the burner management RESET button The panel is mounted on or adjacent to the air handler
234 FUEL GAS SYSTEM
The PILOT LINE comprises 1 Pilot governor (PV1 ) 2 One British Gas certificated solenoid valve (PV2) 3 One pilot gas isolation valve (PV3) 4 Pipework and fittings
Note Two pressure test points are fitted on the pilot line on the inlet and discharge of the pilot solenoid valve
The MAIN GAS LINE comprises
1 Gas isolation valve (MV1 ) 2 Pressure governor (MV2) 3 Double block safety shut-oft system (MV34) 4 Gas flow control valve (MV5) 5 Burner isolation valve (MV6) 6 Pipework and fittings
Note Four pressure test points are fitted on the n1ain gas line on the supply the inlet and discharge of the second block valve and downstream of the flow control valve
Note On small air handlers items 2 and 3 are combined in one multi-functional control
All items above are detailed on the Process amp Instrumentation Diagram in Section 1 of this manual
JULY 1999 SAMPLE Page 9
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
2 GENERAL DESCRIPTION 3000S
235 REMOTE CONTROL STATION
The ECONO-AIR 3000S Series air handler is also supplied with a remote control station which houses the air handler operating controls indicating status and the workspace temperature detector if the control station is located in the heated space
236 HEATED SPACE TEMPERATURE SENSOR The heated space temperature sensor is to be located remotely within the space to be heated
JULY 1999 SAMPLE Page 10
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 30005
31 STATUTORY REQUIREMENTS
I n accordance with the Gas Safety (I nstallation and Use) Regulations 1998 installation of this ECONO-AIR 3000S Series air handler should only be undertaken by competent personnel who are fully aware of their responsibilities under the Health and Safety at Work Act 1974
The installation of this air handler must comply with
BS6230-1991 Installation of gas-fired forced convection air air handlers for commercial and industrial Space Heating of rated input exceeding 60kW
The lEE Regulations for Electrical Installations
Gas Safety (Installation and Use) Regulations 1998
Health and Safety at Work Act 1974
Building Regulations 1986
Building Standards (Scotland Only)
The I nstitution of Gas Engineers Codes of Practice
IGEUP1 Soundness Testing Procedures for Industrial and Commercial Gas Installations
IGEUP2 Gas Installation Pipework Boosters and Compressors on Industrial and Commercial Premises
IGEUP4 Commissioning Of Gas Fired Plant On Industrial and Commercial Premises
32 RECEPTION AND STORAGE OF GOODS
32laquo1 RECEPTION
On receipt of the shipment check that the shipment is complete against the Delivery Advice Note Check for mechanical damage sustained during transit before off-loading the goods Inform the carrier of any such damage
322 OFFLOADING
Horizontal air handlers are fitted with four lifting eyes to permit an overhead lift Alternatively horizontal air handlers may be handled by a fork lift truck on the steel angle support frame
323 STORAGE
Air handlers must be stored in a dry environment The remote control station must be removed from the shipment and stored indoors in a dry environment Outdoor units of split case design (Size 54 and above) must have open ends protected from the environment until installation is complete Any filter elements should be stored in a dry environment
JULY 1999 SAMPLE Page 11
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
33 LIMITATIONS OF USE
The ECONO-AIR 3000S Series air handler must not be installed in the following locations
I n hazardous areas
In areas where flammable vapours can be present in excess of their threshold limit values as defined in 8S5925
I n accordance with 8S6230 Clause 513 where there are any flued appliances in the heated area and where air is supplied mechanically and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will not be at a lower pressure than the outside air If the air handler is the only source of mechanically supplied air the extract rate must not exceed 95 of the nominal air flow specified in Section 11 of this manual
Note If it proposed to install the ECONO-AIR 3000S Series air handler to supply heated air to a hazardous area or in areas where flammable vapours are present the installation must first be approved by a RS STOKVIS Ltd Engineer
34 LOCATION OF AIR HANDLERS
The air handler should normally be installed in the location recommended by the RS STOKVIS Ltd specifying engineer
Check the proposed location for level and load bearing strength Ensure that there is adequate clearance as detailed on the air handler GA in Section 1 this manual around the unit for access for maintenance purposes If the air handler is to be installed above floor level a suitably designed service platform should be provided Such a platform must have 100mm minimum raised edges around the perimeter If this is not possible all air handler access panels must be fitted with hinged restraints This is a factory standard option which should be specified at the time of ordering - check the restraints are fitted before proceeding with installation
JULY 1999 SAMPLE Page 12
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
35 FRESH AIR INLET AND VENTILATION
351 FRESH AIR INLET
The air handler must be installed where it has a direct and unlimited supply of fresh air from outside the building Ensure that the air intake is not located near exhausts from the building or from any process exhausts such as paint booth exhausts Whenever possible protect the fresh air inlet from the prevailing wind and local wind effects from corners
The fresh air inlet should be sized for an air velocity of 3ms The inlet duct area is detailed on the General Arrangement drawing located in Section 1 of this manual
Where the fresh air inlet is made in a load bearing wall eg a brick wall guidance should be obtained from Structural Engineers on the provision of a lintel in the wall over the fresh air opening
A weather hood must be fitted when the air handler air inlet is at or within 1 m of the outside wall Additionally the weather hood should have negligible resistance to the airflow maximum 01 mbar at the design air flow rate
Do not install the ECONO-AI R 3000S Series air handler where long lengths of duct or bends of an angle greater than 30deg are necessary to lead to the air handler from the fresh air opening If ducting is unavoidable ensure that the resulting pressure drop is negligible Le less than 01 mbar for ductless air handlers and has been accounted for in the original design for ducted air handlers as detailed in the specification section of this manual Section 11
Note If the air intake is located in an area of unrestricted access warning notices preventing the blockage of the air intake by temporary stacking should be displayed adjacent to the intake
JULY 1999 SAMPLE Page 13
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
352 VENTI LA TION
Where the air air handler is in its own plant room or compartment this shall be ventilated with openings communicating directly with the outside air to ventilate the room
The openings shall be fitted with grilles of negligible resistance and shall be sited so that they cannot easily be blocked or flooded They shall have a total minimum free area as follows
Low Level (inlet) 320cm2 + 27cm2 per kilowatt in excess of 60kW total rated input
High Level (outlet) 160cm2 + 134cm2 per kilowatt in excess of 60kW total rated input
The free area of the grilles shall be not less than the size of the recommended minimum ventilation opening Grilles shall be designed to minimise high velocity air streams in the plant room For exposed ie free standing plant rooms ventilation openings shall be provided on at least two sides and preferably on all four sides
Where mechanical ventilation is used it shall be by mechanical inlet and either natural or mechanical extraction Systems of ventilation employing mechanical extraction and natural air inlet shall not be used
The minimum flow rates of air supplied shall be not less than 06 m3s per megawatt of rated heat input
36 AIR DISCHARGE
The air handler should be located with the air discharge into the heated space at a minimum height of 3 metres The air should not discharge directly onto any obstructions and direct discharge on to working personnel should be avoided
If the air discharge is located in an area of unrestricted access warning notices preventing the blockage of the air discharge by temporary stacking should be displayed adjacent to the discharge
Generally it is not necessary to fit distribution ducting to the discharge of the air handler If ducting is required or specified ensure that the resulting pressure drop has been accounted for in the original design specification as detailed in Section 1 of this manual
37 ASSEMBLY AND POSITIONING OF AIR HANDLER
Unless specified at the time of order air handlers will be shipped in sections Discharge heads grilles attenuators duct connecting sections filters rain-hoods etc will be supplied loose for site fitting to the air handler
Horizontal air handlers must be supported on their steel angle support base When the air handler is located check for level and adjust as necessary
Alternatively horizontal air handlers can be supplied with extensions of the support frame for suspending from overhead supports This must be specified at the time of order Do not suspend the air handler from the lifting eyes
JULY 1999 SAMPLE Page 14
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
38 REMOTE STATION
The ECONO-AIR 3000S Series air handler is supplied with a remote control station This should be mounted in a position convenient to the end user If possible it should not be mounted on an external wall or where the space temperature detector is affected by cold draughts or a local source of heat
39 VISUAL CHECK
After completion of installation re-check the air handler for signs of damage Report any instance to RS STOKVIS Ltd
310 CONNECTION OF SERVICES
The air handler requires the connection of fuel gas and electricity
3101 FUEL GAS SUPPLY
The ECONO-AIR 3000S Series air handler has been designed for use on Natural Gas An alternative version is available for LPG The gas type for the air handler supplied is clearly marked on the air handler data badge and on the Specification sheet in Section 1 of this manual Check the gas type is correct and that the supply pressure is within the range marked on the specification
The local gas Authority should be consulted about the adequacy of the gas service and meter supplies for existing and proposed extensions to the installation and for any requirements for boosting the gas supply_
Connect the fuel gas supply to the inlet manual valve on the air handler gas train The connection size is detailed in Section 1 of this manual A further isolation valve and union should be fitted immediately adjacent to the appliance which when the valve is closed allows the complete burner and control assembly to be disconnected for maintenance or repair
New gas pipework should be installed to British Gas Publication IGEUP2 and be purged and pressure tested in accordance with British Gas Publications IGEUP1
JULY 1999 SAMPLE Page 15
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
3102 ELECTRICITY SUPPLY
All external wiring shall be carried out and checked by a competent person All components shall be checked for suitability for voltage range and frequency
Means for electric isolation having a contact separation of at least 3mm in all poles must be provided adjacent to the air handler The electrical supply to the appliance shall incorporate suitable means of excess current protection
The ECONO-AIR 3000S Series air handler requires a 3 phase 4 wire supply which should be connected to the main control panel Check the air handler data badge for the correct electrical supply The maximum supply requirement is Specified in Section 1 of this manual Note that the 240 Volt air handler control circuit is taken from the lUI phase to Neutral Connection should be made as shown on the wiring diagram shipped inside this panel
The air handler must be earthed in accordance with BS5986 and CP1013
Check all terminal strip terminations for wires which have become loose during shipment
311 CONNECTION TO THE MAIN PANEL AND REMOTE STATION
Interconnecting wiring to the main panel and remote station should be made with a minimum specification of 075 mm2 300 Volt cable Check that no wires on the terminal strip have become loose during shipment The remote panel should be mounted at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
Both panel and remote station must be earthed in accordance with BS5986 and CP1013
312 HEATED SPACE TEMPERATURE SENSOR
The space temperature sensor located on the remote panel should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted on the remote panel or adjacent to the outlet at a height of approx 18m If possible it should not be mounted on an external wall or where the sensor will be affected by cold draughts or a local source of heat
313 DUCT SENSOR
The duct sensor should be connected with screened cable or twin low voltage signal cable run in its own separate conduit It should be mounted in the air handler discharge as close as possible to the discharge into the heated space
314 OVERHEAT LIMIT CONTROL SENSOR
The overheat limit control sensor should be connected with twin core cable It should be mounted in the air handler discharge within 1 metre of the air handler outlet connection
JULY 1999 SAMPLE Page 16
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
315 TOUCH SCREEN WIRING
The touch screen located on the front of the remote station requires two separate twisted pairs of O5mrh2 screened cable run in a separate conduit If the distance between the main and remote stations is greater that 1 km please contact RS STOKVIS Ltd for advice
JULY 1999 SAMPLE Page 17
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
316 ALIGNMENT
3161 INSTALLATION OF DRIVE BELTS
On 80 amp 89 30008 range of air handlers it will be necessary to align the pulleys and fit the drive belts before carrying out commissioning of the unit
3162 PU LLEYS
Before assembling the drive check the pulley grooves are free from scores or sharp edges and all dimensions conform to the relevant standard
The Taper Lock bush is your starting point when it comes to assembly and installation Drive installation is a straightforward job with Taper Lock - but the stages set out on the installation leaflet provided with every Taper Lock bush should be followed closely
3163 ALIGNMENT
Good alignment of pulleys prior to belt installation is important to avoid belt flank wear The diagram below shows correct installation of pulleys
INTERNAl BEARING
MOTOR PUlLEY rAN PULLEY
MOTORMOTOR ADJUSTMENT MOUNTING BOlTSBOLTS
3164 BELTS
When the pulleys have been correctly positioned on the shafts the belts can be installed to complete the drive
The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force Under no circumstances must belts be prised into the grooves Using sharp tools to stretch the belts over the pulley rim can easily damage belts and pulley grooves
The installation allowance given in the table below is the minimum recommended reduction in centre distance for various belt section and lengths to allow for correct fitting
The take-up allowance given in the same table should be added on to the calculated centre distance to allow for belt stretch
MONTH 1999 SAMPLE Page 18
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
3 INSTALLATION 3000S
3165 INSTALLATION AND TAKE UP ALLOWANCE
Belt Pitch Installation Allowance Take-Up Length (mm) SPZ SPA SPB SPC (mm)
410 to 530 5
540 to 840 10
850 to 1160 15
1170 to 1500 20
1510 to 1830 20 25
1840 to 2170 30
2180 to 2830 25 40
2840 to 3500 30 50
3520 to 4160 50 60
4170 to 5140 70
5220 to 6150 85
6180 to 7500 105
600 to 8500 125
8880 to 10170 145
10600 to 12500 175
MONTH 1999 SAMPLE Page 19
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
4 COMMISSIONING 30005
This appliance must be commissioned by a RS STOKVIS Ltd approved engineer
41 PRESTART CHECKS
1 Switch the SUMMERIOFFMlINTER switch on the remote station to OFF
2 Check the correct electric supply is available to the air handler and the appliance isolator installed
3 Check the correct fuel gas supply is available to the air handler and local isolation valve and union installed Check that new gas pipe work has been correctly purged and pressure tested and that the isolation valve is in the OFF position
4 Check the air handler gas control system and burner connections for pressure soundness as detailed in Appendix 1 of this manual
5 Complete the first section of the Service Check Sheet supplied at the back of this manual (Appendix 3)
6 Close the air handler access door
7 Close and lock the main air handler control panel
8 Switch the main panel isolator to position 1 Check the POWER ON light illuminates
9 Check and set the timed ONOFF periods in the lAC Controller located on the remote panel Ensure that the unit is set to be on during testing Refer to Appendix 4 for the lAC setting procedure
10 Close and lock the remote panel
11 Switch the SUMMERIOFFIWINTER switch on the remote station to SUMMER to start the air fan Return the switch to the OFF position and check for correct rotation of the fan as the fan slows and stops
The fan rotation can be observed through the fan section access door or through the air handler access door Only do this during the fan run-down period Ensure the door is securely fastened after completion
Rotation arrows are fitted on the end of the air handler and inside the air handler above the interior bearing support If the rotation is incorrect two phases should be interchanged as dictated by the Engineer responsible for the site electrical system
12 Check the air pressure drop across the burner whilst the fan is operating with a water column pressure gauge connected to the two pressure test points on the air pressure switch (DPS) This pressure should be between 14 and 16 rnbar
If the air differential pressure measured above is not within the operating range check inlet and outlet ductwork as appropriate and any filters fitted If the pressure differential is still not within limits isolate the air handler and report to RS STOKVIS Ltd before proceeding
13 Check the operation and setting of the Low Air Pressure Switch by injecting a controlled signal into the switch Check the break point on the switch is 1 mbar (falling)
Note The switch is set and sealed before fitting The 1 mbar switch point may not coincide with the 1 mbar scale reading on the switch
If on checking the switch is not operating correctly do not tamper with it return it to RS STOKVIS Ltd for replacement
MONTH 1999 SAMPLE Page 20
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
4 COMMISSIONING 3000S
42 DRY RUN
With all the manual gas isolation valves still in the OFF position switch the SUMMERIOFFIWINTER switch to WINTER
43 START UP
1 Attach a manometer to pressure test point F and the low pressure test point on the air pressure switch (DPS)
2 Open the main gas supply valve (MV1) and the pilot burner isolation valve (PV3) Leave the main burner isolation valve (MV6) closed Reset the air handler by pressing the push-button marked RESET on either the main panel or remote station The air handler pilot will light automatically (after the automatic damper start check and combustion air pre-purge) and then LOCKOUT after the main gas shut-off valves are addressed
During the short period that the pilot is in operation check the pilot gas pressure on the manometer It should be 10 mbar and the pilot flame approximately 100 - 150mm in length covering the first three or four holes of the mixing plate and have a steady blue colour when viewed through the sight glass on the access side of the air handler Adjust as necessary - refer to Section 51 this manual Check the flame signal - refer to Section 431
3 Open the main burner isolation valve (MV6) RESET the air handler which should now light to main burner stage When alight close the main burner isolation valve to shut down the gas flow to the burner Check that the unit goes to LOCKOUT
4 Reset the air handler and drive the burner to low fire by adjusting the temperature controller set point as described in Appendix 4 of this manual Check the flame is continuous across the width of the burner and has a flame length of approx 50 - 65mm from the burner rail when viewed through the sight glass on the access side of the air handler Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch ie on the rear of the pressure switch This pressure is specifled in Section 1 of this manual Adjust as necessary-refer to Section 53 of this manual Check the flame signal - refer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
5 Drive the burner to high fire by adjusting the temperature controller set point and high limit to 55degC as described in Appendix 4 of this manual Check the flame is continuous across the burner rail and has a flame length of approximately 250 - 350mm from the burner rail Check the burner pressure across pressure test point D and the downstream (low) pressure test point on the air pressure switch This pressure is specified in Section 1 of this manual Adjust as necessary - refer to Section 52 of this manual Check the maximum air handler discharge temperature Check the flame signal shyrefer to Section 431
Where possible check the actual gas flow rate by meter reading with all other appliances turned off
6 Check the operation of the overheat limit control by adjusting the temperature controller set point and high limit to 65degC as described in Appendix 4 of this manual Monitor the discharge temperature on the temperature controller Check that the overheat control operates as the set temperature is passed Check that the control must be manually reset by pressing the green reset button on the front of the switch Return the temperature controller to its original settings
In the event that the ambient temperature is too low for this simple procedure to work the instrument will have to be bench tested using a Temperature 8ath Remove and replace the control as Section 84 of this manual for bench-testing
MONTH 1999 SAMPLE Page 21
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
4 COMMISSIONING 3000S
43 1 FLAME SIGNAL CHECK
1 The ECONO-AIR 3000S Series air handler is fitted with a Klippon SAKT1 Test Terminal which can be used to measure the flame scanning signal Refer to the Electrical Schematic and connect a 0-1 mA ammeter to the two test points with standard 23 mm test plugs with the positive lead on the detector side Disconnect the terminal link to obtain the signal reading A minimum signal of 70 microamps is required typical signals are in the 250-400 microamp range on both pilot and main flame After completion replace the terminal link and remove the test jacks
2 Drive the burner to high fire as previously described Measure the carbon dioxide content of the discharge air stream This figure must not exceed 2800 ppm If the discharge exceeds this limit isolate the air handler and report to RS STOKVIS Ltd before proceeding
Stop and start the air handler a few times to check for reliability using the Operating Instructions (Section 6)
432 HANDOVER
Complete the air handler Service Check Sheet supplied at the back of this manual The self-copy sheet must be returned to STOKVIS for checking
Instruct the User in efficient use and care of the unit start-up and shutdown (including emergency shutdown) and recommended service interval Emphasise the need to keep the air handler clear of stored items and extraneous material and to maintain the recirculation and fresh air paths to the air handler inlets Hand all instructions as applicable to the UserOwner for safekeeping
MONTH 1999 SAMPLE Page 22
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
5 ADJUSTMENTS 3000S
If adjustments to the air handler settings are required they should be made by a RS STOKVIS Ltd approved engineer
The normal value for all control settings is specified in Section 1 of this manual
51 PILOT ADJUSTMENT
The pilot gas pressure and flame length may be adjusted by altering the discharge pressure of the pilot governor Screwing the adjusting screw clockwise (located under the top cap) increases the discharge pressure and the flame length anti-clockwise decreases the pressure and the flame length
52 BURNER HIGH FIRE PRESSURE ADJUSTMENT
At high fire alter the spring compression on the main burner governor (MV2) by removing the cap and adjust the spring compression plate clockwise to increase the burner pressure anti-clockwise to decrease burner pressure If the pressure does not increase on adjusting the spring the supply is inadequate
Note On small air handlers fitted with a mUlti-functional control the pressure adjusting screw is located under a swing cap on the first block valve
53 BURNER LOW FIRE ADJUSTMENT
The main burner low fire is adjusted on the flow control valve MV5 (Process amp Instrumentation Diagram)
Remove the top cover of the valve and insert a Terminal Screwdriver in the adjusting screw of the TOP cam marked NI
Drive the burner to low fire by adjusting the temperature controller set-point and high limit to 05degC as described in Appendix 4 of this manual
Turn the Terminal Screwdriver clockwise to decrease the low fire gas flow anti-clockwise to increase the flow
Check the heat input and flame signal at the new position are satisfactory and return the tenlperature controller to its normal settings
Replace the control valve cover
MONTH 1999 SAMPLE Page 23
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
5 ADJUSTMENTS 3000S
54 SUMMERIOFFIWINTER SWITCH
In the SUMMER position this switch provides ventilation only and is independent of the programmed ON and OFF periods This position is manually selected and must be manually de-selected Whenever the switch is in this position the fan is operating
In the OFF position the air handler is shutdown and will not operate This overrides any frost protection fitted It is suitable for air handler shutdown for short periods such as holidays The programme memory is unaffected by this switch and assumes control of the air handler when the switch is returned to the WINTER position
In the WINTER position the air handler operates off the programme memory to provide heating
55 RESET BUTTON
Visual indication of air handler lockout is provided In the event of lockout occurring the air handler can be reset by depressing the RESET button This parallels the RESET button on the air handler main control panel If after 4 attempts to reset the air handler the lockout indicator still illuminates then a Service Engineer should be called to investigate the problem
MONTH 1999 SAMPLE Page 24
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
6 OPERATING INSTRUCTIONS 3000S
61 AIR HANDLER START-UP
1 Open all manual gas valves both on the appliance and on the supply to the appliance Switch on the Electric Supply to the appliance
2 On the main air handler panel
Switch the panel isolator to the 1 position
Check POWER ON light
3 On the remote control station
For Heating Switch the SUMMERIOFFIWINTER switch to WINTER
The air handler will now start automatically in response to the time settings
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
For Unheated Ventilation Switch the SUMMERIOFFIWINTER switch to SUMMER
Note This prevents the burner firing giving a controlled supply of ventilation air to the heated space as long as the switch is in this position The air handler will now start automatically in response to the timeclock demand To turn the fan off return the switch to the centre OFF position
In the event of LOCKOUT
Press the RESET button and the cycle of operations will be repeated If the air handler goes to LOCKOUT four times in succession call for a Service Engineer
62 AIR HANDLER SHUTDOWN
621 SHUTDOWN FOR SHORT PERIODS
Switch the SUMMERIOFFIWINTER switch on the remote station to OFF
622 SHUTDOWN FOR PROLONGED PERIODS
Switch the main panel isolator to the 0 position and close all manual gas valves both on and leading to the appliance
Note Manual gas valves should only be operated when the appliance is to be shut off for either Servicing or for a prolonged shutdown
MONTH 1999 SAMPLE Page 25
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
30005 6 OPERATING INSTRUCTIONS
63 GENERAL INSTRUCTIONS
631 SITE CLEARANCE ADJACENT TO AIR HANDLER
Attention should be paid to keeping the area around the air handler tidy No rubbish should be allowed to accumulate in the vicinity of the air handler and storage of goods etc should not be permitted within two metres of the air handler Failure to comply could result in reduced airflow to the air handler causing inefficient running and potential overheat cond ition
632 AIR SUPPLY TO AIR HANDLER
Air vents and grilles supplying air to the air handler should never be blocked and should be checked periodically to ensure they are clear
633 AIR FILTERS
Similarly attention should be paid to cleaning or replacing the filters to the air handler if fitted Your installer should advise you on the frequency with which this would be required to be completed
634 SERVICE
For continued safe and efficient operation of this air air handler it is important that servicing of the air handler should be completed at regular intervals by a competent person in accordance with Section 82 of this manual Users are advised to enter into a Service Agreement with RS STOKVIS Ltd
635 SPARE PARTS
It is suggested that a complete set of spare parts essential to the running of the air handler and recommended by the installer are kept by the user on the premises where the air handler is installed This is particularly important where the air handler forms an essential part of any process plant and its being out of operation may cause problems by for example frost damage or condensation by super-cooling
A list of Recommended Spares will be found in Section 9 of this manual
636 GAS LEAKS
If a smell of gas is detected around the area of the appliance Switch off all manual gas valves and contact your service engineer or the local gas undertaking
NEVER
LOOK FOR GAS LEAKS WITH A LIGHTED MATCH OR NAKED
FLAME
MONTH 1999 SAMPLE Page 26
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
7 FAULT FINDING 30008
The main control panel incorporates two lights to help in fault finding
POWER ON
LOCKOUT
The remote station also has three lights
AIR FAN ON
BURNER ON
LOCKOUT
This section gives the possible causes of failure associated with each check light The electrical schematic diagram in this manual and the wiring diagram shipped in the main air handler panel should be used in conjunction with the notes below Additionally Service Engineers should familiarise themselves with the detailed Start Sequence given in Appendix 2 of this manual
The notes are given for each light before consulting the notes check for bulb failure
71 POWER ON LIGHT IS UNLIT
Check
1 Main control panel isolator is in the 1 position
2 Main Panel 6A MCB has not tripped if a trip has occurred the switch will be at the OFF position Reset and test system as required
3 Also check if the mains electrical supply is isolated If so FIND OUT WHY before taking any action
MONTH 1999 SAMPLE Page 27
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
7 FAULT FINDING 30005
72 AIR FAN ON LIGHT IS UNLIT
Check
1 SUMMERIOFFIWINTER switch is not in Position OFF
2 Timeperiod is not set to off
3 Air handler is not at LOCKOUT
4 Recheck both AIR FAN ON and LOCKOUT bulbs
Two fault indications are possible
1 THE FAN IS NOT OPERATING
If the fan should have started but is not operating
Check 1 Overload for tripped conditions Reset the overload and monitor the next start-up
2 Motor Fuses
3 Relays 1 2 amp3 for failure
laClor CC1 for failure
5 Air Pressure Switch (DPS) is failed in the N 0 Position
Replace the faulty component as described in Section 8
2 THE FAN IS OPERATING
This indicates that the air pressure switch (DPS) has failed to change over
Measure the profile plate differential pressure as described in Section 4113 If the pressure is correct the air pressure switch is faulty Check the switch as in 4114 If the pressure is not correct
Check 1 Correct fan belt tension
2 Correct fan rotation
3 The air handler air inlets and discharge are not blocked
4 Correct fitting on filters
5 The air differential pressure switch impulse lines are not blocked or leaking
MONTH 1999 SAMPLE Page 28
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
7 FAULT FINDING 30008
73 LOCKOUT LIGHT IS ILLUMINATED
This light indicates a failure in the burner ignition and flame supervision system
RESET the unit and follow the progress of the start sequence The full cycle may take two minutes
1
------t
2 LOCKOUT after 35-40 seconds indicates an ignition failure RESET the system and observe the pilot and ignition spark during the start-up attempt
I-- shy
3 Observe the spark This should be strong and highly visible If not remove and clean the spark plug as Section 82 Check that the spark plug gap is correctly set at 15 mm
-- shy
4 Check the pilot flame If the pilot flame ignites and the unit goes to LOCKOUT the scanning system is at fault Remove and clean the detector as Section 82 Check the flame signal as in Section 431
5 If the pilot does not light the gas supply system is faulty Check the pilot system for restriction and the pilot valve operation
6 If the pilot lights and the unit goes to LOCKOUT after the main gas valves are addressed either the flow control valve is blocked or one of the main gas block valves has failed Fit a manometer on the pressure test point on the outlet flange of the multishyfunctional control and observe if the pressure rises when the main gas valves are addressed No pressure rise will indicate failure of the main gas valves
74 AIR FAN ON LIGHT ILLUMINATED
If the burner does not start check
1 SUMMERIOFFIWINTER switch is in WINTER position
2 Overheat Limit Control
These interlocks prevent the burner management system starting
MONTH 1999 SAMPLE Page 29
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
IMPORTANT Servicing and maintenance should be only carried out by a RS STOKVIS Ltd approved engineer
Only use replacement parts provided by the appliance manufacturer
Check that the air openings for combustion and for ventilation of any plant roon or compartment are clear
81 ISOLATION
811 FUEL GAS ISOLATION
The fuel gas to the ECONO-AIR 3000S Series air handler should be isolated and locked off at the manual ball valve mounted at the start of the fuel gas line Additionally before entering or servicing the air handler the burner manual isolation valve and pilot line isolation valve should be closed
812 ELECTRICAL ISOLATION
All electric power to the air handler and the remote control station is switched through the local isolator This isolator is fitted with a lock facility to permit it to be locked in the OFF position
Additionally isolate the power at the Wall Isolator
MONTH 1999 SAMPLE Page 30
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 30005
82 ROUTINE MAINTENANCE
The air handler should be routinely serviced at the start of each heating season Isolate the air handler as above before servicing Details of access to individual components are given in Section 84 of this manual
1 Remove and clean spark igniter Check that the gap is correctly set at 25 mm Replace every two years
2 Clean the flame detector lens to ensure freedom from dirt and moisture If the cell shows any sign of cracks it should be replaced Routinely replace the cell every two years or after 10000 hours of operation which ever comes first
3 Inspect the entire air handler paint system for general damage Repair as necessary
4 Every two years brush the burner plates and clear the burner holes carefully with a Size 18mm drill for NP II and 20mm drill for NP I
WARNING THE BURNER HOLES MUST NOT BE ENLARGED
5 Inspect and lubricate all damper linkages to ensure freedom of operation Wipe off all excess lubricants to prevent dirt build up on linkage parts
6 Check the fan belt for cracks and splits Check tension The correct tension gives 16mm deflection per metre of span when the belt is centrally loaded with a force of 27N Adjust as necessary
7 Grease both the fan shaft bearings with Mobiith AW2 grease or similar
NEVER use high temperature grease
NEVER mix two different greases within the bearing always flush existing grease out
Note Removing the cover plate on the end of the air handler gains access to the outboard fan bearing
Light to Slow to 0 120 2 to 6 months Clean Dry
Medium Medium 120 200 1 to 2 months
Moderate to Light to Slow to 0 120 1 to 4 weeks Dry
Dirty Medium Medium 120 200 1 to 7 days
Extreme Dirt Dry Light to Slow to 0 200 Daily Flushing out
Medium Medium Dirt
83 ANNUAL SERVICE CHECKS
After Servicing test fire the air handler following the Commissioning Procedure detailed in Section 4 of this manual to ensure correct operation generally Special attention must be paid to the damper system and related controls and interlocks
Additionally check that the fresh air and recirculation air entry path to the air handler has been kept clear and instruct the User of the need for this as necessary
MONTH 1999 SAMPLE Page 31
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
84 REMOVAL PROCEDURE FOR REPLACEABLE COMPONENTS
IMPORTANT
Turn off the gas at the appliance service valve and the electricity at the main panel and wall isolator before proceeding
841 BURNER
The burner is located inside the air handler casing and is mounted on two brackets from the support straps To remove the burner isolate the air handler as in 81 and undo the union on the fuel gas line adjacent to the burner isolation valve (MV6) and unscrew the main and pilot gas feed pipes from the burner rail Access to the rear of the burner assembly is made by removing the partition plate below the burner separating the fresh air inlet to the burner from the return air inlet compartment This is held in place by screws which engage in captive nuts on the top side of the partition Remove the Flame Detector and pull off the ignition plug cap Disconnect the burner support brackets and remove the burner The burner will easily pass through the access hatch for further strip down Replace in the reverse order soundness test the gas pipework check the burner operation and duty as described in the commissioning section of this manual
842 FLAME DETECTOR
This is a 240 Volt instrument
The flame detector is mounted on the end of the burner rail inside the air handler casing To remove the detector isolate the panel electric supply and lock off Push the scanner towards the burner and rotate to release the bayonet fixing and lift the detector from its mount Remove the two screws holding the detector cover and disconnect the supply leads noting the polarity of the connections
Replace the flame detector in the reverse order ensuring correct polarity of connections Ensure the access panel is securely closed and the retaining nuts are tightened down Check operation by inserting a test meter in the points provided in the main control panel and reading the flame signals during start up to full rate burner operation (See 431) Operate the appliance over six starts for reliability of operation including tum off of start and main gas valves to check for lockout operation
843 IGNITER SPARK PLUG
This is a high tension spark plug
The igniter spark plug is mounted on the end of the burner rail inside the air handler casing To remove the spark plug isolate the air handler as above Enter the service access door Access to the spark plug is made through the profile plate To remove the spark plug pull off the high tension lead and unscrew the plug with a plug spanner
When replacing the spark plug check the plug gap is set at 15mm Check ignition reliability over six start ups
MONTH 1999 SAMPLE Page 32
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
844 IGNITER SPARK TRANSFORMER
This is a 240 Volt instrument
The ignition transformer is located in a plastic box mounted on the air handler casing adjacent to the main control panel To remove the transformer isolate the air handler as above and unscrew the four retaining screws holding the box lid in place and remove the lid Disconnect the supply cable at the terminal strip and undo the transformer retaining screws The transformer may then be unscrewed from the High Tension cable leading to the spark plug
Replacement is a simple reversal of this procedure
Check ignition reliability over six start ups
845 COMBUSTION AIR PRESSURE SWITCH (DPS)
Note The switch is set and sealed and should be replaced if not operating correctly
This switch is a 240 Volt instrument
The air switch is mounted directly on the air handler casing and can be serviced in situ However if it is necessary to remove the switch isolate the air handler as above Disconnect the supply cable Break the downstream pipe compression fitting and unscrew the switch housing from its locating fitting Reverse the procedure to replace after ensuring switch setting is as specified in Section 13 of this manual Operate the air handler to ensure reliability of operation over six start ups
846 AIR HANDLER OVERHEAT LIMIT CONTROL
This is a 240 Volt instrument
The overheat limit control can be serviced in situ However if it is necessary to remove the control isolate the air handler as above and lock off Remove the switch cover Disconnect the supply cable and unscrew the control housing from its locating fitting Reverse the procedure to replace check the switch is set to 50degC Test the switch operation as described in Section 43 over at least three operations
847 AIR FAN AND MOTOR
The air fan motor is a 415 Volt 3 phase motor
The motor and slide rails are easily accessible inside the air handler casing If it is necessary to remove the motor isolate the air handler as above Slacken the fan-belt tension and remove the drive belts Pull the motor away from the air handler casing to make access to the motor terminal box and disconnect the supply cable The motor may now be removed from the unit Following replacement the air handler must be fully re-commissioned as in Section 4
It is unlikely that the air fan will need replacing or servicing If required a full procedure should be obtained from RS STOKVIS Ltd
Replacement must be followed by full re-commissioning as in Section 4
MONTH 1999 SAMPLE Page 33
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
848 FUEL GAS MULTI-FUNCTIONAL CONTROL - SMALL UNITS
This is a 240 Volt instrument
The fuel gas multi-functional control can be serviced in situ However if it is necessary to remove the unit isolate the air handler as above Disconnect the Hirschman electric termination Unbolt the control from its flanges and remove
When replacing care must be taken to ensure the flange 0 rings are undamaged and in the correct location Following replacement the air handler must be fully reshycommissioned as in Section 4 including tests for soundness prior to start-up
849 GOVERNOR AND BLOCK VALVES
The block valves are 240 Volt instruments
All these items may be serviced in situ However if it is necessary to remove any item isolate the air handler as above Disconnect the electric termination to the two block valves the pilot block valve and the flow control block valve Break the two pipe unions and remove the fuel gas line complete for further strip-down
8410 FUEL GAS FLOW CONTROL VALVE
This is a 24 Volt instrument
The fuel gas How control valve can be serviced in situ However if it is necessary to remove the valve isolate the air handler as above Disconnect the supply cables to the control valve
On small air handlers fitted with a multi-functional control support the multi-functional control and unbolt its discharge flange Break the union downstream of the burner isolation valve and remove the section of line containing the flow control valve for further strip-down
On large air handlers fitted with separate block valves it will be necessary to remove the fuel gas line complete as Section 8410 above
Following replacement re-commission the air handler
Note If the fresh air damper is not in the full open position the heat input must not exceed the maximum heat input at recirculation condition specified in the technical data section of this manual
8411 PILOT GAS GOVERNOR AND BLOCK VALVE
The block valve is a 240 Volt instrument
Both items may be serviced in situ However if it is necessary to remove either item isolate the air handler as above Disconnect the electric terrriination to the solenoid valve Undo the upstream pipe union and the compression fitting downstream of the manual block valve (PV3) Remove the pilot gas line complete for further strip down
Replace broken or distorted connections and retest for soundness Ensure the pilot gas pressure is correct and the flame is sensing an output Ensure reliability over six start-ups
MONTH 1999 SAMPLE Page 34
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
8412 BELT TENSIONING PROCEDURE
The setting tensions are designed to cover a wide range of drives A precise setting force for individual applications can be calculated as detailed
SETTING FORCES
Belt Section
Setting Force To Deflect Belt 16mm per Metre Of Span
Small Pulley Diameter (mm)
Basic Setting Forces Newtons (N) Kilograms (kgf)
125 x Setting Forces Newtons (N) Kilograms (kgf)
SPZ
56 to 71 16 16 20 20 75 to 90 18 18 22 22
95 to 125 20 20 25 25 Over 125 22 22 28 28
SPA
80 to 100 22 22 28 28 106 to 140 30 30 38 38 150 to 200 36 37 45 46 Over 200 40 40 50 51
SPB
112 to 160 40 40 50 51 170 to 224 50 51 62 63 236 to 355 62 63 77 79 Over 355 65 66 81 83
SPC 224 to 250 70 71 87 89 265 to 355 92 94 115 120 Over 375 115 120 144 150
MONTH 1999 SAMPLE Page 35
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
BELT TENSIONING USING FENNER BELT TENSION INDICATOR
Calculate the deflection in mm on a basis of 16mm per metre of centre distance Centre Distance (m) x 16 =Deflection (mm)
Set lower marker ring at the deflection distance required in mm on the lower scale
Set upper ring against to bottom edge of the top tube
Place the belt tension indicator on top of the belt at the centre of span and apply a force at right angles to the belt defecting it to the point where the lower marker ring is level with the top of the adjacent belt
Read off the force value indicated by the top edge of the upper marker ring
Compare this force to the kgf value shown in the table above
If a Fenner Belt Tension Indicator is not available a spring balance and rule will be suffice
MONTH 1999 SAMPLE Page 36
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 30005
85 MAIN PANEL CONTROLS
All panel controls are readily accessible and may be easily exchanged for replacement components in the event of failure Ensure any replacement item is of the same make and type as the original
851 LANDIS amp GYR LFL 1335 AUTOMATIC SEQUENCE CONTROLLER
The Landis amp Gyr Automatic Sequence Controller is a plug-in unit locating on a pre-wired chassis To remove the controller undo the two retaining screws at the top left and lower right corners and pull the module off the chassis
Replacement is a simple reversal of the above procedure
852 CONTROLS CIRCUIT (24 VOLT) TRANSFORMER
The Controls Circuit Transformer is fixed to the panel back plate by tapped screws To remove the transformer undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Undo the two retaining screws and remove the unit complete
Replacement is a simple reversal of the above procedure
853 CONTROL RELAYS R1 R2 amp R3
The Control Relays are DIN Rail mounted To remove a relay undo the wIring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the relay with a screwdriver and remove the relay
Replacement is a simple reversal of the above procedure
854 6A MCB
The 6A MCB is DIN Rail mounted To remove the MCB undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the MCB with a screwdriver and remove the MCB
Replacement is a simple reversal of the above procedure
855 THERMAL OVERLOAD
The thermal overload is attached to the underside of the main contactor To remove the overload undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel and that the overload setting is as specified in Section 13 of this manual Unscrew the three connections to the contactor and remove the overload
Replacement is a simple reversal of the above procedure
MONTH 1999 SAMPLE Page 37
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
8 SERVICING 3000S
856 MAIN CONTACTOR
The Main Contactor is DIN Rail mounted To remove the contactor remove the thermal overload as 855 above and then undo the wiring connections after first noting that the connections are correct to the wiring diagram attached to the panel Release the DIN rail retaining clip under the contactor with a screwdriver and remove the contactor
Replacement is a simple reversal of the above procedure
857 MOTOR FUSE
To replace a motor fuse pull the fuse carrier off the fuse holder base The fuse is attached to the fuse carrier by two screws Unscrew remove and replace
86 REMOTE CONTROL STATION
The remote control station contains some serviceable parts although these items should only be fitted by an approved RS STOKVIS Ltd Engineer
MONTH 1999 SAMPLE Page 38
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
9 RECOMMENDED SPARES 3000S
For two years operation it is recommended that the following items should be held in stock
ITEM DESCRIPTION PART NO QUANTITY i
1 INDICATOR BULBS W1121 1 PACK
2 SPARK PLUG 023739 1 I
3 UVDETECTOR QRA10C 1 I
4 ROOM SENSOR DRT2453 1
5 DUCT SENSOR DDT1701 1
All replacement parts can be obtained from RS STOKVIS Ltd by quoting the air handler serial number the part number and description
MONTH 1999 SAMPLE Page 39
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 1 30005
SOUNDNESS TESTING THE FUEL GAS PIPEWORK
This procedure should only be carried out by personnel familiar with the ECONO-AIR 3000S Series Air handler
The pressure test points and all valves are identified on the Process and Instrumentation Diagram for the air handler included in Section 1 of this n1anual
Isolate the air handler electric supply at the main control panel and lock off Close the manual isolation valves MV1 MV6 and PV3 Ensure the supply pressure is available on the upstream side of MV1
A11 TESTING THE UPSTREAM PIPEWORKAND BURNER CONTROLS 1 Connect a 60 mbar manometer to the pressure test nipple A Monitor the
pressure for two minutes Any rise in pressure indicates that valve MV1 is leaking and must be replaced Remove pressure test points Band F
2 Open MV1 to pressurise the pipework on both the main gas and pilot line to the first block valve
3 Close MV1 Allow one minute for the temperature to stabilise and then test the system for 2 minutes and watch for a drop in the pipework pressure If the pressure falls open valve MV1 and test the pipework connections and valves from MV1 to MV3 and MV1 to PV2 for leaks with a proprietary leak detector fluid or spray Turn off MV1 seal any leaks and re-test
4 If no extemalleaks are found either the pilot block valve PV1 or either the first main gas block valve MV3 is letting by
5 To test this seal pressure test point A and fit a manometer to pressure test point B Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the block valve MV3 Turn off MV1 exchange the valve and re-test from point 2 above
6 Repeat this procedure for the pilot block valve Seal test point B and fit a manometer to pressure test point F Leave for two minutes with MV1 open A rise in pressure on the manometer confirms a leak on the pilot block valve PV2 Turn off MV1 exchange the valve and re-test from point 1 above Seal test point F
MONTH 1999 SAMPLE Page 40
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 1 30005
A12 TESTING THE DOWNSTREAM BURNER VALVE 1 Close MV1 and connect pressure test points A and 8 with flexible 6 mm bore
tubing teed into the manometer Remove pressure test point C Open MV1 to pressurise the downstream block valve MV4
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the two block valves MV3 and MV4 with a proprietary leak detector Turn off MV1 seal any leaks and re-test Note Smaller air handlers in the 3000S Series are fitted with multi-functional valves combining the pressure regulator and two block valves in one component The above procedure still applies but if a leak is found on either block valve the whole control should be replaced If no external leaks are found the downstream block valve is letting by
3 To confirm this close MV1 remove the manometer and refit to pressure test point C Connect pressure test points A and 8 with flexible 6mm bore tubing Open MV1 and allow one minute for the temperature to stabilise Monitor the pressure for a further 2 minutes with MV1 still open A rise in pressure confirms that the second block valve MV4 is letting by Turn off MV1 Replace the valve and re-test from 2 above
A13 TESTING THE DOWNSTREAM BURNER PIPEWORK 1 Close MV1 and connect pressure test points A and D with flexible 6 mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one minute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve MV4 and the manual block MV6 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve MV6 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
A14 TESTING THE DOWNSTREAM PILOT PIPEWORK 1 Close MV1 and connect pressure test points A and F with flexible 6mm bore
tubing teed into the manometer Open MV1 to pressurise the downstream pilot pipework
2 Close MV1 and leave for one rninute for the temperature to stabilise Monitor the pressure for 2 minutes If the pressure falls open valve MV1 and leak test the line between the downstream block valve PV2 and the manual block PV3 with a proprietary leak detector fluid or spray If no external leaks are found the manual block valve PV3 is letting by Turn off MV1 seal any leakages and reshytest from 2 above
MONTH 1999 SAMPLE Page 41
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 1 30005
A15 TESTING THE BURNER CONNECTIONS 1 Remove the burner access panel as described in Section 84 of this manual
Remove the burner spark igniter Slacken the two retaining bolts holding the burner to the burner support straps and unbolt the burner supply endplate from the burner casting and mixing plates
2 Connect pressure test points A and 0 with flexible 6mm bore tubing teed into the manometer Open MV1 and MV6 to pressurise the burner pipework Leak test the main gas burner pipework and connections with proprietary leak detector fluid Turn off MV6 Seal any leakages and re-test
3 Connect pressure test points A and F with flexible 6 mm bore tubing teed into the manometer Open MV1 and PV3 to pressurise the pilot burner pipework Leak test the pilot gas burner pipework and connections with proprietary leak detector fluid Turn off PV3 Seal any leakages and re-test
4 Turn off MV1
5 Replace the spark igniter and profile division plate
MONTH 1999 SAMPLE Page 42
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 2 30005
START SEQUENCE
The burner start sequence is controlled by the Landis and Gyr burner management unit The timings are pre-set and comply with 885885 This unit must NOT be tampered with
A brief description of the start-up sequence isshy
The unit checks
1 The NO FLAME signal on the UV flame scanner
Note If the scanner detects a flame at any time other than in the correct operating sequence the flame programmer initiates a lockout
2 The operation of the combustion air proving switch in the NO AIR position
3 The air handler discharge high temperature switch
If the checks are completed the unit starts the combustion air fan and then checks the combustion airflow
Once the airflow is proven the unit checks that the damper control circuit is functioning correctly After the damper microswitch is made to prove the fresh air damper is fully open the sequence allows 30 seconds for the combustion air to purge any combustible gas from the air handler
After completion of the purge the spark ignition system is energised the pilot valve opened and the spark terminated If the pilot flame is not proven by the UV scanner the system will initiate a LOCKOUT
If the flame is proven the main gas valves are opened the pilot extinguished and the main burner flame proven
MONTH 1999 SAMPLE Page 43
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
i
APPENDIX 2 30008
The following flow chart shows the complete start sequence including the lighting of the various indicating lamps
MANUAL STATUS LIGHT POWER ON
POWER ON
I INITIATE START BY TIME
SETTING ON CONTROLLER
I CHECK NO FLAME
VISIBLE
PROVEj FAIL LOCKOUT
I CHECK RELAY R4 NC
POSITION
PROVE FAIL NO START
I CHECK AIR PRESSURE SWITCH NC POSITION
PROVE FAIL NO START
I CHECK RELAY R1 NC
POSITION
PROVE j
FAIL NO START
I START COMBUSTION
AIR BLOWER
I CHECK AIR PRESSURE SWITCH NO POSITION
PROVE I
FAIL NO START
I STATUS LIGHT FAN ON
I ENERGISE RELAY R1
I
MONTH 1999 SAMPLE Page 44
I
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
I
APPENDIX 2 30008
I CHECK OVERHEAT LIMIT
CONTROL R5
PROVE I
FAIL I I
CHECK 541412 LOOP CLOSED ON
LANDIS ampGYR CIRCUIT
PROVE I
FAIL I I
COMBUSTION AIR PURGE PERIOD
30 SECONDS
I
NO START
NO START
CANCEL NO FLAME CHECK CIRCUIT
I
ENERGISE SPARK
I TIMED PERIOD 25 SECONDS
I ENERGISE PILOT GAS
VALVE
I TIMED PERIOD 25 SECONDS
I TERMINATE SPARK
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
TIMED PERIOD 10 SECONDS
I
LOCKOUT
MONTH 1999 SAMPLE Page 45
I
I
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 2 3000S
I ENERGISE MAIN GAS
VALVES
I
STATUS LIGHT BURNER ON
I TIMED PERIOD
5 SECONDS
I DE-ENERGISE PILOT
GAS VALVES
CONTINUOUS FROM PILOT
I INTERROGATE UV FLAME SCANNER
PROVE I
FAIL I I
LOCKOUT I
MONTH 1999 SAMPLE Page 46
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 3 30005
Please see copy of Standard Service Sheet
MONTH 1999 SAMPLE Page 47
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30005
A41 TIME OUT SCREEN
This is the standard screen displayed when the touch screen is not in use The back light is off to save energy_ To access the STATUS screen touch the ENTER key and the following screen is displayed
[]][I][]rn[IJOO[][IJOO[] EJ~E11 I[]I ~ middot I
NOTE
The Touch Screen operates using the heat produced by the touch of a finger and therefore only LIGHT pressure is required
Excessive pressure can damage the Touch Screen
MONTH 1999 SAMPLE Page 48
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
A42 STATUS SCREEN
On the typical STATUS screen the illustrated information detailed is as follows
19 36 Fan Brn
RS OS
100 Fst_~_ Lck _ _ Xst Gas~o ~ I
RS Indicates the current room temperature
OS ~( t~~ the current duct discharge temperature
Fan Indicates the current status of the fan by showing the arrow and the fan blades for ON and OFF is shown by the arrow and fan blades being removed
Brn Indicates the current status of the burner with the black flames indicating the burner to be ON and vice versa
Lck LOCKOUT - This indicates a flame failure when highlighted during normal or start-up operation
Xst EXCESS TEMPERATURE SWITCH - This indicates the unit has reached the trip limit on the over heat stat when highlighted during operation
Indicates the current position of the gas modulating valve during normal Gas
operation (0-100)
Indicates whether the Frost stat is energised and the unit is running on frost Fst
override
MONTH 1999 SAMPLE Page 49
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
A43 CHANGING SETTINGS
It is possible to change the settings for the time of operation and the required temperature set points The following details the steps required
A44 ENTERING THE SECURITY CODE
From the STATUS screen touch the return key and the screen below will be displayed
Type the HIGH LEVEL security code (4321) If you make a mistake use the BACK SPACE key to delete any incorrect number(s) Touch the ENTER key when the code is correct
If the security code is incorrect the screen above will be displayed then try again If after several attempts you can not gain access please contact RS STOKVIS Ltd for further information
MONTH 1999 SAMPLE Page 50
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
When the code is entered correctly the MAIN MENU is displayed as detailed below
~ STATUS SET VALUES~ ~ TIVIE CLOCK [) [) [) [) [)
The MAIN MENU screen shows the three menu items available The title for each menu item can be changed to suit the end user Please notify RS STOKVIS Ltd prior to commissioning should these parameters require special amendments
MONTH 1999 SAMPLE Page 51
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
A45 CHANGING OR SETTING A TIME SCHEDULE
From the main menu screen select the TIME CLOCK page by running finger across screen symbol and touch the ENTER key the screen below will be displayed
On the following screen highlight the TS1 symbol and touch the ENTER key
The current time schedule will now be displayed as shown below The display will automatically default to the current day (1 =Monday 2 =Tuesday etc) In this case day 5 (Friday) the four schedule switching times refer to that day
IAC6BBB1BHIS1
mm0CIl bull mID 17BB 17BB 17HB
Iillleschedule
To modify a time select it by highlighting and touch the ENTER key and the following screen is displayed
To amend the appropriate onoff time as shown on the screen below The arrows to the right of the time are for altering the hours and the arrows on the left for the minutes
Once you have set the time use the ESCape key to exit back to the time schedule screen and choose another day by touching the required number Another time may now be modified as before
IAC6BBB1BHIS1
H8BH
I i eschedule
MONTH 1999 SAMPLE Page 52
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
Use the ESCape key to exit back to the MAIN MENU screen
~ STATUS ~ SET VALUES
TIME CLOCK []~ [] [] [] []
MONTH 1999 SAMPLE Page 53
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30005
A46 CHANGING SET VALUES
From the main menu screen select the SET VALUES page by highlight in the normal way and touch the ENTER key
The following screen is displayed
36 19 18III III IIIHsv Rsv Llv
To change the RSV highlight it in the normal way and touch the ENTER key and the screen below will now be shown
IAC6RRR1RR40 T I
0 19 (Y)l RSV
ROOM SET VALUE
The above screen shows the parameters that can be changed The values to the far left are the limitations of set point (OC) Change the set point by using the UP and DOWN ARROWS on the left of the screen or touch the set value itself followed by the ENTER key to select the set value and set it directly using the numeric keyboard All values can be changed in this way
Use the ESCape key twice to exit back to the MAIN MENU screen
MONTH 1999 SAMPLE Page 54
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30005
A47 COMMISSIONING AND SERVICING BURNER CHECKS
Select the SET VALUES screen from the MAIN MENU screen and adjust the high lirrlit set point to 55degC to drive the burner to high fire
IAC6HHH1HH60 ~T I
0 19 (Y)
HSV
HIGH SET VALUE ~
Ensure the set value is returned to 36degC once the appropriate checks and adjustments as described in Section 43 of this manual have been completed Return to the SET VALUES screen and select the low limit value to adjust the low fire setting
Reduce the low limit value to OdegC to drive the gas valve to low fire and complete the appropriate checks and adjustments as described in Section 43 of this manual and ensure the set value is returned to the original value
A48 GMT ltgt BST CHANGEOVER DAYLIGHT SAVINGS
To change your unit to British Summer TimelWinter Time the following system screen must be highlighted by touching the Iamp1 button twice
By touching the clock symbol in the top left hand corner followed by the ENTER key the screen below will be displayed
MONTH 1999 SAMPLE Page 55
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
APPENDIX 4 30008
188311 851193
544
By touching and highlighting in this case 18 followed by the ENTER key A small box allowing the entry of two digits will appear Enter the desired time required using the numbered keys followed by ENTER key Your unit is now set to operate on BSTBWT
Touch the ESC key three times to return back to the Status screen
MONTH 1999 SAMPLE Page 56
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999
STOKVIS ENERGY SYSTEMS 96R WALTON ROAD EAST MOLESEY SURREY KT8 0DL TEL 020 8783 3050 08707 707 747 FAX 020 8783 3051 08707 707 767 E-MAIL infostokvisboilerscom WEBSITE wwwstokvisboilerscom
JULY 1999