Nortek NRV24M, NRV32M, NRV38M, NRV46M Installation And Operating Manual

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Page 1

Nor-Ray-Vac Modulating

Continous Radiant Tube System

WARNINGS

Nortek Global HVAC (UK) Limited equipment must be installed and maintained in accordance with the

requirements of the Codes of Practice or rules in force. All external wiring MUST comply with the codes of practice

or rules in force in the country of installation.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.

Read instructions before installing or servicing this equipment. Gas-ﬁred appliances are not designed for use in

hazardous atmospheres containing ﬂammable vapours or combustible dust, containing chlorinated or halogenated

hydrocarbons, or in applications with airborne silicone substances.

Reznor® Is a registered trademark of Nortek Global HVAC, LLC.

INSTALLATION AND OPERATING MANUAL

ErP

2018

Part No. D301040

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Any reference made to Laws, Standards, Directives, Codes of Practice or other recommendations governing the application and installation of heating appliances and which may be referred to in Brochures, Specications, Quotations, and Installation, Operation and Maintenance manuals is done so for information and guidance purposes only and should only be considered valid at the time of the publication. The Manufacturer cannot be held responsible from any matters arising from the revision to or introduction of new Laws, Standards, Directives, Codes of Practice or other recommendations.

IMPORTANT NOTICE TO INSTALLERS

Installers should satisfy themselves that the gas pipework installation is carried out in accordance with all current legislation, Codes of Practice and recommendations .

Additionally it may be necessary to protect the gas valves which form part of the heater or burner assembly from potential pipe contamination particularly, but not exclusively, where copper gas pipework is used.

In instances where copper pipework is to be used for all or part of a gas pipework installation, including short length nal connections then we advise that installers consult with gas supplier or provider and satisfy themselves what additional precautions may be necessary.

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Document Index.

1 Installation Requirements

1.1 Compliance Notices

1.2 Certicate of Conformity

1.3 General Product Information

1.4 Model Denitions

1.5 General requirements

1.6 Delivery and Pre-Installation Checks

1.7 Health & Safety

1.8 Heater Suspension

1.9 Clearance to Combustibles

1.10 Gas Connection & Supply Details

1.11 Electrical Connections

1.11.1 Typical Wiring Schematic

1.11.2 Wiring Details

1.12 Ventilation Requirements

1.13 Flue System

1.13.1 Gen eral

1.13.2 Flue Installation

1.13.3 Exhaust Considerations

1.13.4 Ducted Air Considerations

1.14 Vacuum Fan Details

1.15 Technical Data

2 Assembly Instructions SEE BOOKLET 2, DOCUMENT REF 700071

3 Commissioning Instructions

3.1 Tools Required

3.2 General

3.3 Commissioning Procedure

3.3.1 Start Up Checks

3.3.1.9 Burner Timer Dip-switch Settings

3.4 Schneider Inverter Driven Mod Fans B80, B160, B300

3.5 Schneider Inverter Driven Fans B80, B160, B300 Mod Branch Damper (Zonal Modulation)

3.6 ABB Inverter Driven BH300 Mod Fan

3.7 ABB Inverter Driven Fan BH300 Mod. Branch Damper (Zonal Modulation)

3.8 Damper Setup

3.9 Non-inverter Driven Fans, Mod Branch Dampers (Zonal Modulation)

3.10 Non-inverter Driven Fans Mod Fan Damper (System Modulation)

3.11 Final Commissioning

3.12.1 System Layout via 1ph Inverter

3.12.2 System Layout via Zonal Branch Damper

3.12.3 System Layout via System Fan Damper

4 Servicing Instructions

4.1 Tools Required

4.2 Burner Exploded Views

4.3 Vacuum Fan

4.4 Radiant Tubes

4.5 Tube Couplers

4.6 Reectors

4.7 Flue Condensate Trap

4.8 Burner Electrode Assembly

4.9 Burner Head

4.10 Filter

4.11 Combustion Chamber Viewing Window

4.12 Flue Assembly

5 Spare Parts

5.1 Required Spares List

5.2 Injector/Air Shutter Selection

6 Fault Finding Guide

7 Replacing Parts

7.1 Removal of Burner Assembly

7.2 Controller Replacement

7.3 Gas Valve Replacement

7.4 Filter Replacement

7.5 Pressure Switch Replacement

7.6 Electrode Assembly Replacement

7.7 Injector Replacement

7.8 Combustion Chamber Window Replacement

8 User and Operating Instructions

8.1 To Start Heater

8.2 To Switch O the Heater

8.3 Routine Maintenance Between Service Intervals

8.4 Frequency of Servicing

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Introduction.

elcome to the range of Nor-Ray-Vac ‘M’ series

modulating continuous radiant tube heaters. The Nor-Ray-Vac ‘M’ series modulating system complies with the requirements of the European Gas Appliance Directive and BS EN777-4. Local regulations may vary in the country of use and it is the installers responsibility to ensure that such regulations are satised.

All installation, assembly, commissioning and service procedures must be carried out by suitable qualied competent persons to the statutory regulations in the country of use.

When assembling, installing, commissioning and servicing is undertaken on radiant tube heaters specied in these instructions, due care and attention is required to ensure that working at height regulations are adhered to at the mounting heights specied.

PLEASE READ this document prior to installation and

use. The safety of this heater is guaranteed only by the correct usage in accordance with these instructions, therefore it is recommended that they are retained for future reference.

All Dimensions shown are in mm unless otherwise stated.

The manufacturer reserves the right to alter specications without prior notice.

1. Installation Requirements.



Isolate any electrical supply to the heater and

controller before proceeding. 

1.1 Compliance notices

he Nor-Ray-Vac ‘M’ series detailed herewith is manufactured within a strictly controlled quality

environment within the parameters of ISO 9001.

These instructions are only valid if the following country code is on the appliance GB. IE. If this code is not present on the appliance, it is necessary to refer to the technical instructions which will provide the necessary information concerning the modication of then appliance to the conditions of use for the country.

The Nor-Ray-Vac ‘M’ series has been tested and assessed for compliance with the following European Directives.

Gas Appliance Directive: (90/396/ EEC) Machinery Directive: (2006/42/EC) Low Voltage Directive: (2006/95/EC) Electromagnetic Compatibility Directive: (2004/108/EC) Product Liability Directive: (85/374/EEC)

The manufacturer has taken reasonable and practical steps to ensure that the Nor-Ray-Vac ‘M’ series modulating system is safe and without risk when properly used. These heaters should therefore only be used in the manner and purpose for which they were intended, and in accordance with the recommendations detailed herewith.

The heaters have been designed, manufactured, assembled, inspected, and tested, with safety and quality in mind, there are certain basic precautions which the installer and user should be aware of, and they are strongly advised to read the appropriate sections of the information pack accompanying the heater, prior to installation or use.

The Manufacturer supports all new products being supplied to their customers with a comprehensive information pack; this clearly denes mandatory instructions for the safe installation, use, and maintenance, of the appliance(s).

Where proprietary items are incorporated into Nor-Ray-Vac ‘M’ System, detailed information and instructions are also provided as part of the information pack.

It is the responsibility of the installer, owner, user, or hirer, of the Nor-Ray-Vac ‘M’ Systems, to ensure that they are familiar with the appropriate information/manuals, supplied by the manufacturer, and that they are suitably aware of the purpose of the manuals and the safety instructions. In addition, operators must be suitably trained in the use of the appliance so as to ensure its continued safe and ecient use.

The Manufacturer has a commitment to continuous improvement and therefore reserves the right to amend or change the specication of the Nor-Ray-Vac ‘M’ series subject to compliance with the appropriate European, national, and local regulations.

Contained within the text of the manual, the words ‘Caution’ and ‘Warning’ are used to highlight certain points.

Caution is used when failure to follow or implement the instruction(s) can lead to premature failure or damage to the heater or

its component parts.

Warning is used when failure to heed or implement the instruction(s) can lead to not only component damage, but also to a

hazardous situation being created where there is a risk of personal injury.

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The Nor-Ray-Vac ‘M’ series conforms to the following harmonised standards:

BS EN 292 -1 Safety of Machinery - Basic Concepts, General Principles for

Design Basic terminology, methodology BS EN 292-2.

Safety of Machinery - Basic Concepts, General Principles for Design Technical Principles and Specications.

BS EN 60204-1 Safety of Machinery - Electrical Equipment for Machines

Specication for General Requirements.

BS EN 60335-1 Safety of Household and Similar Electrical Appliances

General Requirements

BS EN 55014 Limits and methods of measurement of radio disturbance

characteristics of electrical motor-operated and thermal appliances for household and similar purposes, electrical tools and similar electric apparatus.

BS EN 50165 Electrical Equipment of non-electric heating appliances for

household and similar purposes, safety requirements.

1.2 Certicates of conformity

Certicates are available from the manufacturer, address details are shown on the back page.

Notied body Pin reference is : 86CP52

1.3 General product information

The Nor-Ray-Vac ‘M’ series radiant heating system comprises of a modulating continuous system with a number of burners located in series in a radiant branch, and a number of radiant branches manifolded together, linked by a tail pipe to a vacuum fan discharging the spent products of combustion to atmosphere. A system may comprise of just one burner and one vacuum fan, to multiple burners in multiple radiant branches with one or more vacuum fans.

To enable exact matching of operational needs within an area, distances between burners and ratings of the burners can vary. The unique feature of Nor-Ray-Vac ‘M’ series is a modulating radiant system which provides uniform heat coverage of the oor area, eliminating hot/cold spots.

The tube into which the burners are mounted and over which the reectors are tted and emits the maximum heat is called the radiant tube. The radiant heat emitted from the hot tube is directed downwards by reectors. The remaining interconnecting tube is called the tail pipe and radiates with less intensity.

The operating temperatures of the tubes generally range from 200°C – 480°C max.

The action of the vacuum fan is three fold; to create a high negative pressure within the radiant tube and tail pipe so as to discharge the spent products of combustion from the system to a point outside the building being heated; to control the ow of gas and air through each burner in stoichiometric proportions; to draw carrier air into the tube system at the start of each radiant branch, in order to distribute the heat from the ame along the tube.

Ducted air inlet kits are also available for contaminated or dusty environments.

Each heater is tted with a burner which has been test red and pre-set prior to despatch. The safety functions of the burner are by way of a fully sequential control box tted to the burner.

Note

Neither asbestos nor soft soldered joints are used in the construction or manufacture of the Nor-Ray-Vac ‘M’ series. The materials selected for use can withstand the mechanical, chemical, and thermal stresses which they will be subject to during foreseen normal use when installed in accordance with the manufacturers recommendations.



1.4 Model Denitions

 NRVxxM-EV = Nor-Ray-Vac modulating continuous radiant

tube heater only for use with branch end congurations.

NRVxxM-IL = Nor-Ray-Vac modulating continuous radiant tube heater only for use with in-line congurations.

xx denotes kW rating. Models available; 24, 32, 38 and 46

1.5 General requirements

Caution

Before installation, check that the local distribution conditions, nature of gas and pressure, and adjustment of the appliance are compatible.

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1.6 Delivery and pre-installation checks.

On receipt of the heater, the following checks should be carried out;

• The model is as per order.

• That it is undamaged.

• That it is suitable for the fuel supply.

• That it is suitable for the electrical supply.

If any of these points are not satised then contact should be made with the Sales Oce at Nortek Global HVAC (UK) Limited as soon as possible by telephoning 01384 489250. In the case of claims for damage, this must be signed for as damaged and reported in writing within 24 hours of delivery, in order to comply with insurance criteria.

1.7 Health and Safety



Warning

Nor-Ray-Vac ‘M’ series must be installed in accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998. Due account should also be taken of any obligations arising from the Health and Safety at Works Act 1974 or relevant codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring regulations (BS 7671), BS 6896: (Industrial & Commercial) and any other relevant British Standards and Codes of Practice by a qualied installer. Isolate all electrical supplies to the heater & controller before proceeding.



Caution

For your own safety we recommend the use of Personal Protective Equipment during installation.



1.8 Heater Suspension



First considerations

Clearances from combustibles must be maintained. (See g

2).

For ease of servicing there should be a minimum clearance distance of 500mm between the burners of the heating system and the building wall. This measurement can be reduced for perimeter type systems. (See gure 1a). For ease of servicing and burner removal minimum clearances should be maintained. (See gure 1b and 1c). In exceptional circumstances the burner lid may be slid diagonally for removal thus reducing the vertical distance.

Ensure that the suspension is suciently exible to allow for thermal expansion.

Installation and assembly procedures must be carried out by suitable competent persons. Commissioning and service procedures must be carried out by suitable qualied persons.

Warning

Unauthorised modications to the appliance, or departure from the manufacturers guidance on intended use, or, installation contrary to the manufacturers recommendations may constitute a hazard.

The Nor-Ray-Vac system as designed and supplied shall not be altered without consultation and approval from Nortek Global HVAC (UK) Limited.

Note

To ignore the warning and caution notices, and to ignore the advice from the manufacturer on installation, commissioning, servicing, or use, will jeopardise any applicable warranty, moreover, such a situation could also compromise the safe and ecient running of the appliance itself, and thereby constitute a hazard.

The installation of the appliance must meet all the relevant European, national, and local criteria.

Prior to installation the following points should be considered;

• The position of the heater for the optimum ecient distribution.

• The position of the heater relative to the route of the ue.

• The position of the heater relative to the supply of gas.

• The position of the heater relative to the electrical services, and if appropriate, any additional controls.

• The position of the heater relative to the supply of fresh air if applicable.

• The position of the heater relative to service and maintenance requirements.

Caution

The heater must not be installed within an area where the conditions are unsuitable, e.g. where the atmosphere is highly corrosive, has a high degree of salinity, or where high wind velocities may aect burner operation. Suitable protection should be provided for the appliance when it is located in a position where it may be susceptible to external mechanical damage from; for example, fork lift trucks, overhead cranes etc.

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Suspending the heater - General

The rst support is always positioned at the support lug suspension point on the end vent burner combustion chamber.

Subsequent supports are placed approximately 2.8m apart, including one at each combustion chamber location. This gives a maximum load per support of 24kg.

A support must always be located at a maximum distance of 2m from a tee or elbow tting.

Except for the combustion chamber support lug suspension points, suspension support brackets are installed to support the tube section which is then covered with reectors.

Tail pipe hangers are installed for the tube section which will be without reectors.

If there are any doubts as to the strength or suitability of roof steelwork to which heaters are to be suspended, please refer to a Consultant, Architect or owner of the building.

The manifold should be supported by chain, stainless steel

exible wire, or other exible means from the roof structure to allow movement caused by thermal expansion. The maximum distance between supports is

1.5m for horizontal runs.  Wall bands are not load bearing and give lateral support

only. If used, wall bands should be tted every 3m on vertical runs to ensure the system is rigidly held. The system should be braced immediately below passing through the roof line to ensure the ashing does not suer lateral pressures.

Table 1. Minimum mounting heights

The recommended mounting heights for Nor-Ray-Vac ‘M’ heaters are given in the table below.

Recommended Mounting Height (m)

Model Horizontal

NRV24M 4.0M

NRV32M 4.7M

NRV38M 5.7M

NRV46M 6.0M

g. 1.a Overall dimensions

A Burner Tube B Burner

C Optional Perimeter Reector D Side wall

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g. 1.b Clearance for servicing - distances to walls and obstacles above.

g. 1.c Clearance for servicing - distances to obstacles above.

B Reector D Side wall E Obstacle above F End cap G Burner Lid

B Reector E Obstacle above F End cap G Burner Lid

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1.9 Clearance to Combustibles.

The minimum clearances to combustible materials are given below. These minimum distances MUST be adhered to at all times

Figure 2 Diagram illustrating the clearance to combustibles

Burner Model NRV24M NRV32M

End Vent In-line End Vent In-line

Below tube

Dim D - without undershield 1120 1250 1440 1700

Dim D - with undershield 760 850 760 850

Dim C - above tube 250 250 250 250

Horizontally

Dim B - standard reector 600 770 700 850

Dim A - perimeter reector 305 450 305 510

Burner Model NRV38M NRV46M

End Vent In-line End Vent In-line

Dim D - without undershield 1570 2100 170 0 2100

Dim D - with undershield 785 1050 850 1050

Dim C - above tube 250 250 250 250

Horizontally

Dim B - standard reector 700 1000 700 1000

Dim A - perimeter reector 305 600 305 600

Distance from combustibles (distance from heat source that will produce a 50ºC rise in temperature above ambient of a black surface) A Radiant tube; B Standard reector; C Combustible material underneath; D Combustible material on side; E Combustible material above; F Perimeter reector;

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1.10 Gas Connection and Supply

Before installation, check that the local distribution conditions, nature of gas and pressure, and adjustment of the appliance are compatible.

A competent or qualied engineer is required to either install a new gas meter to the service pipe or to check that the existing meter is adequate to deal with the rate of gas supply required.

Installation pipes should be tted in accordance with BS 6896, so that the supply pressure, as stated in Table 3 will be achieved. It is the responsibility of the competent engineer to ensure that other relevant Standards and Codes of Practice are complied with in the country of installation. Pipes of smaller size than the heater inlet gas connection must not be used. The complete installation must be tested for soundness as described in the country of installation.

A gas isolation valve must be tted immediately adjacent to each burner unit which, when closed, allow the complete burner unit to be disconnected for maintenance or repair.

Take care when making a gas connection to the heater

not to apply excessive turning force to the internal controls.

A exible hose is installed to allow safe linear expansion to each burner without creating undue stress on the gas supply pipe work. It is therefore important that a tested and certied hose assembly made to ISO 10380, supplied with ½” BSP female cone seat adapters, is installed as per these instructions.

It is also important to ensure that expansion is taken up in the body of the exible hose, and not on its attachment to the pipe work.

The cone seat adapter supplied on one end of the exible gas hose provides a `swivel` action, and must be tted on the burner using a ½” BSP barrel nipple to provide ease of disconnection for future servicing.

The installation layout described below is the only method recommended by the institute of gas engineers, the hose manufacturer, and Nortek Global HVAC (UK) Limited and must only be carried out by a qualied/competent gas engineer.

Gas Category G20 G31

Gas type Natural Gas Propane

Maximum supply pressure mbar 50 57. 5

Minimum supply pressure mbar 17. 5 25

Gas supply 20 37

Table 3 Gas Supply Pressures

g.3. Correct installation of exible gas connection

Depending on the specic installation, the exible gas hose may be routed to the gas cock at any of the following angles in relation to the burner:

Vertical (g.a) 45° angle (g.b) 90° angle (g.c) Any other position in between these angles is acceptable.

g.a g.b g.c

Care must be taken to observe the minimum pipe bend diameter (minimum 250mm, maximum 350mm) & pipe expansion distance (minimum 30mm, maximum 70mm) as shown opposite

Maximum bend diameter for the hose is 450mm.

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The correct installation as shown below will allow for approx 100mm of movement due to expansion

The methods shown below are unacceptable, due to undue stress on the hose & ttings.

1.11 Electrical Connections

• Standard burner 16W.

• Current rating 0.05 amp per burner

• Fuse: external 2 amp Slow Blow.

Each component carrying an electrical supply must be

earthed.

• Supply to burners is 230V 50Hz single phase.

• Exhaust fans are three phase 415V 50Hz.*

• IP54 rated Inverter panel LRU’s for B80/B160/B300 require a 230V single phase supply at 22A (B80/B160) or 30A (B300).

• IP54 rated Inverter panel LRU’s for BH300 require a 4125V three phase supply at 30A.

• Standard LRU’s require a 415V three phase supply at 25A (BH300 Non-inverter driven only).*

* refer to individual site specications.

All electrical work should be carried out to IEE standards by a competent electrician.

The electrical connection to the burner is made by means of a three pin plug-in-power connector. Live , neutral and earth connections should be made via a exible supply cable to the power connector and routed clear of the heater

or tubes.

The exible supply cables to each burner should be of

0.5mm² minimum and comply with BS 6500. For fan and LRU supply, the wire size must be suitable for the current ratings as listed in Table 10.

The wires in the mains lead are coloured in accordance with the following code: Green & Yellow Earth; Blue Neutral; Brown Live.

The method of connection to the electrical supply must facilitate complete isolation and should be via a fused double pole isolator having contact separation of at least 3mm on all poles and supplying the appliance only.

We recommend use of Nortek Global HVAC (UK) Limited approved controls. Please refer to SmartCom control manual for siting and installation details and gures 4.l and

4.m Where alternative controls are used, please refer to the manufactures instructions for their siting and installation details.

The controller shall have the means to allow the system to be turned o and on at least once in a 24hour period to facilitate a pressure switch check. The controller also requires the facility of a 0-10VDC output to modulate the system and MUST be programmed to provide 5 minutes high re when there is a demand for heat before modulating the system.

Note: where Smartcom controllers are used only use those with software version 3.1 or higher.

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Figure 4.a. Typical Burner Wiring Connections - single leg shown

3. Connect a mains lead from the secondary

2A switched fused spur to the

FIRST IN-LINE BURNER ONLY.

A suitable 3 core cable is then looped from this fused spur to a further 2A

switched fused spur positioned adjacent to the

NEXT IN-LINE BURNER.

This burner is wired to the fused spur by a mains lead.

4. Repeat step 3 for any subsequent

IN-LINE BURNERS within the same

radiant branch only.

2. A 3 pin at plug is wired in suitable 3 core

cable and connected to the ‘Power Out’

socket of the

END VENT BURNER. The cable

is then terminated at a2A switched fused spur

adjacent to the

FIRST IN-LINE BURNER.

Secondary

3A Switched

Fused Spur

2A Switched

Fused Spur

To other in-line burners,

in the radiant branch

In-line Burner

End Vent Burner

End Vent

Burner

In-line

Burner

‘Power out’ from End

Vent Burner to In-Line

Burner(s). (Do not allow

cable to rest on the

radiant system)

230V 50Hz

Switched Supply

from Control Source

1. 230V switched supply from the

control source is connected to the

END VENT BURNER ONLY

with a

mains lead via a 2A switched fused spur.

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1.11.1.1 NRV ‘M’ system - Typical External Diagram

Networking Cable

Screened pair Beldon

9841 or equiv

0-10VDC modulation

input via Screened pair

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1.11.1.2 NRV ‘M’ system - Typical External Diagram - Independent Zonal Damper Modulating

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1.11.2 Wiring Details

Figure 4.c. NRV M internal wiring diagram - End Vent Burner (EV)

Figure 4.d. NRV M internal wiring diagram - In-line Burner (IL)

MAIN

GREY

RED

FLAME SENSOR

IGNITOR

BLACK

PURPLE

RED

LAMPS

MAINS

GRN/YEL

BROWN

SOLENOID

GREEN/YELLOW

SWITCH

N.O.

N.C.

BURNER

BLUE

VACUUM

BROWN

VALVE

J.S.T.

BLACK

VALVE

J.S.T.

BLUE

POWER OUT

2345

BLUE

DELAY TIMER

RED

BLUE

MAINS INPUT

EMC FILTER

BLUE

GREEN/YELLOW

BLUE

MAIN

RED

FLAME SENSOR

IGNITOR

PURPLE

RED

LAMPS

MAINS

BROWN

SOLENOID

GREEN/YELLOW

MAINS INPUT

EMC

BURNER

BLUE

BROWN

VALVE

J.S.T.

FILTER

BLACK

VALVE

J.S.T.

BLUE

12345

BLUE

DELAY TIMER

BLUE

BROWN

GRN/YEL

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Figure 4.e. M internal wiring diagram - End Vent Burner c/w N/O or N/C volt free Lockout contacts

Figure 4.f. M internal wiring diagram - In-line Burner c/w N/O or N/C volt free Lockout contacts

MAIN

GREY

GREEN/YELLOW

RED

FLAME SENSOR

IGNITOR

BLACK

PURPLE

RED

LAMPS

MAINS

GRN/YEL

BROWN

SOLENOID

SWITCH

N.O.

N.C.

EMC FILTER

BURNER

BLUE

VACUUM

BROWN

VALVE

J.S.T.

BLACK

VALVE

J.S.T.

BLUE

POWER OUT

2345

BLUE

DELAY TIMER

RED

BLUE

MAINS INPUT

N.O.

N.C.

RELAY

RED

BLUE

GREEN/YELLOW

BLUE

MAIN

RED

FLAME SENSOR

IGNITOR

PURPLE

RED

LAMPS

MAINS

BROWN

SOLENOID

GREEN/YELLOW

BURNER

BLUE

BROWN

VALVE

J.S.T.

BLACK

VALVE

J.S.T.

BLUE

12345

BLUE

DELAY TIMER

BLUE

BROWN

GRN/YEL

MAINS INPUT

N.O.

N.C.

RELAY

RED

EMC FILTER

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Figure 4.g. M internal wiring diagram - End Vent Burner c/w 3 way solenoid valve

Figure 4.h. M internal wiring diagram - End Vent Burner c/w 3 way solenoid valve & N/O or N/C VF Lockout contacts

MAIN

GREY

RED

FLAME SENSOR

IGNITOR

BLACK

PURPLE

RED

LAMPS

MAINS

GRN/YEL

BROWN

SOLENOID

GREEN/YELLOW

SWITCH

N.O.

N.C.

BURNER

BLUE

VACUUM

BROWN

VALVE

J.S.T.

BLACK

VALVE

J.S.T.

BLUE

POWER OUT

2345

BLUE

DELAY TIMER

RED

BLUE

MAINS INPUT

EMC FILTER

BLUE

GRN/YEL

BLUE

RED

SOLENOID

3 WAY AR

RED

BLUE

MAIN

GREY

GRN/YEL

RED

FLAME SENSOR

IGNITOR

BLACK

PURPLE

RED

LAMPS

MAINS

GRN/YEL

BROWN

SOLENOID

SWITCH

N.O.

N.C.

EMC FILTER

BURNER

BLUE

VACUUM

BROWN

VALVE

J.S.T.

BLACK

VALVE

J.S.T.

BLUE

POWER OUT

2345

BLUE

DELAY TIMER

RED

BLUE

MAINS INPUT

N.O.

N.C.

RELAY

RED

BLUE

GRN/YEL

BLUE

RED

SOLENOID

3 WAY AR

BLUE

GRN/YEL

Page 18

Doc No. 700070 Page 18 of 56

Figure 4.j. NRV Inverter Internal Wiring Diagram for B80, B160 and B300 three phase fans

Figure 4.k. NRV Inverter Internal Wiring Diagram for BH300 three phase fans

Circuit

VF Enable

L NL

1 Ph Supply

230V 50Hz

LEN

VU W

3Ph Supply

To Fan

TERMINAL RAIL

Brown

Green/Yellow

Orange

R1A

24V LI1

R/L1 S/L2

R1C

V.S.D.1

W/T3

U/T1

V/T2

E L

230V 50HZ 1 Pha SUPPLY

FAN HEALTHY LAMP

TO FAN

Blue

t1 t2

Brown

Fan Trip

Circuit

Brown

E E

MAINS ON LAMP

Brown

0-10VDC

Modulating

AI1COM

Yellow

Red

t5 t6

Orange

TERMINAL RAIL

Brown

Green/Yellow

Orange

+24V DI1

ROCOM

RONO

V.S.D.1

AI1GND

E L

FAN HEALTHY LAMP

TO FAN

Blue

t1 t2

Brown

MAINS ON LAMP

Brown

Black

Grey

415V 50HZ 3 Pha SUPPLY

Yellow

Red

Orange

Circuit

VF Enable

VU W

3Ph Supply

To Fan

Fan Trip

Circuit

0-10VDC

Modulating

L N

3 Ph Supply

415V 50Hz

E E LL

321 1

L L

321

Page 19

Doc No. 700070 Page 19 of 56

Figure 4.l. Alternate NRV Local Relay Unit Internal Wiring Diagram for BH300 three phase fans

TERMINAL RAIL

Brown

Green/Yellow

98 97

Contactor

E L

415V 50HZ 3 Pha SUPPLY

TO FAN

Blue

t4 t3

3 12

Black

Grey

2 1

Brown

95 A2

FAN HEALTHY

96 A113

MAINS ON LAMP

Circuit

VF Enable

VU W

3Ph Supply

To Fan

Fan Trip

Circuit

0-10VDC

Modulating

NL NL

3 Ph Supply

415V 50Hz

E E LL

321 1

L L

321

Page 20

Doc No. 700070 Page 20 of 56

Supply via Isolator

230V 50Hz 1 Pha

Burners

Zone A

Drawing No. : 900287 MOD R7

3 Phase

Isolator

(HEAT 1 OUTPUT)

(LIVE)

(NEUTRAL)

Note: Connection to the

burners MUST be made

via a 3A fused spur.

(COMMON)

(REMOTE OFF)

eg Door

Remote OFF

(where applicable)

Remote ON

(where applicable)

eg B.M.S.

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

41 40 7 8 14 5 6C 9 25

NEUT

LIVE

Black

Bulb

Sensor

(REMOTE ON)

0-10VDC

Modulating

( MODULATING 0-10VDC)

(0V)

FAN MOTOR

230V 3-Phase Supply.

Motor must be wired

DELTA

IMPORTANT

For Inverter panels only MAXIMUM length of cable

between inverter and fan is 5m (EMC class A building)

or 10m (EMC class B building).

N.B. if in doubt, do not exceed 5m.

Exhaust

Fan

To other slave

controllers

where app.

C2 C0 C1

Supply to inline

burners

SmartCom Mulitizone

(Master if networked)

NOTES:

REMOTE SWITCH INPUTS

should be connected by 0.75mm² cable

Max length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to enable).

Connect to B0 & B1 for remote ON (ie

BMS time control).

Connect to B0 & B2 for remote OFF (ie

door interlock. remote frost etc).

*The power supply is non-isolated, therefore all

wiring to the control must be mains rated.

REMOTE SENSOR(s) may be placed at

a max distance of 100m from the control

unit, using screened 0.75mm² cable.

Wiring should be kept separate from

mains wiring to minimise noise pick up.

Set within Engineers functions for remote

sensor.

THE LOCAL RELAY UNIT

houses

an inverter. This converts the 230V

single-phase input into a three-phase

230V output. The inverter provides

a soft start to the motor, which extends

the motor life by minimising the start

current.

Inverter Local Relay Unit

SUPPLY VIA ISOLATOR

ELECTRICAL INPUT

230V 1P 22A

230V 1P 30A

FAN TYPE

B80

B160

B300

4-Core Armoured or

Screened Cable 1.5mm²

Low Voltage

+24V DC

(FAN CIRCUIT)

Volt free

Fan Trip

Indication

by others

E E L L N N

V W 1 2

5 6

Figure 4.m. NRV M System Schematic interconnecting wiring. B80, B160 and B300 three phase fans. Modulating controlled by SmartCom3 via single phase inverter panel. (single zone shown)

Page 21

Doc No. 700070 Page 21 of 56

Burners

Zone B

To other slave

controllers

SmartCom Mulitizone

Supply via Isolator

230V 50Hz 1 Pha

To other slave

controllers

Supply via Isolator

230V 50Hz 1 Pha

(Slave 1)

Drawing No.: 900287 Mod Damp R8

Note: Connection to the

burners MUST be made

via a 3A fused spur.

Burners

Zone A

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1

B1 B0 B2 C2 C0 C1

66 64 20

40 7 8 14 5 6

C 9 25

eg Door

Remote OFF

(where applicable)

(COMMON)

(REMOTE OFF)

NEUT

LIVE

Black Bulb

Sensor

SmartCom Mulitizone

(Master)

! FUSE RATING

1/L 2/N 10

S/R0

S/R1D0 D1

O0 O1 B1 B0

B2 C2 C0

C1 66 64

40 7 8 14

5 6C

9 25

eg B.M.S. eg Door

Remote ON

(where applicable)

Remote OFF

(where applicable)

(COMMON)

(REMOTE ON)

(REMOTE OFF)

NEUT

LIVE

Black Bulb

Sensor

Supply to inline

burners

Burners

Zone A

Supply to inline

burners

Burners

Zone B

SUPPLY VIA ISOLATOR

ELECTRICAL INPUT

230V 1P 22A

230V 1P 30A

FAN TYPE

B80

B160

B300

Exhaust

Fan

4-Core Armoured or

Screened Cable 1.5mm

FAN MOTOR

230V 3-Phase Supply.

Motor must be wired DELTA

3 Phase

Isolator

Low Voltage +24V DC

Volt Free Circuit

Fan Trip

Indication

by others

THE LOCAL RELAY UNIT

houses

an inverter. This converts the 230V

single-phase input into a three-phase

230V output. The inverter provides

a soft start to the motor, which extends

the motor life by minimising the start

current.

Inverter Local Relay Unit

Modulating

Dampers

Modulating

Dampers

NOTES:

REMOTE SWITCH INPUTS

should be connected by 0.75mm² cable

Max length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to enable).

Connect to B0 & B1 for remote ON (ie

BMS time control).

Connect to B0 & B2 for remote OFF (ie

door interlock. remote frost etc).

*The power supply is non-isolated, therefore all

wiring to the control must be mains rated.

REMOTE SENSOR(s)

may be placed at

a max distance of 100m from the control

unit, using screened 0.75mm² cable.

Wiring should be kept separate from

mains wiring to minimise noise pick up.

Set within Engineers functions for remote

sensor.

IMPORTANT

For Inverter panels only MAXIMUM length of cable

between inverter and fan is 5m (EMC class A building)

or 10m (EMC class B building).

N.B.

if in doubt, do not exceed 5m.

Figure 4.n. NRV M System Schematic interconnecting wiring. B80, B160 and B300 three phase fans. Modulating controlled by SmartCom3 and zonal branch dampers via single phase inverter panel. (1 zone shown)

Page 22

Doc No. 700070 Page 22 of 56

Supply via Isolator

230V 50Hz 1 Pha

Drawing No. : 900289 MOD R9

4-Core Armoured or

Screened Cable 1.5mm²

3 Phase

Isolator

(HEAT 1 OUTPUT)

(LIVE)

(NEUTRAL)

NOTES:

REMOTE SWITCH INPUTS

should be connected by 0.75mm² cable

Max length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to enable).

Connect to B0 & B1 for remote ON (ie

BMS time control).

Connect to B0 & B2 for remote OFF (ie

door interlock. remote frost etc).

*The power supply is non-isolated, therefore all

wiring to the control must be mains rated.

REMOTE SENSOR(s) may be placed at

a max distance of 100m from the control

unit, using screened 0.75mm² cable.

Wiring should be kept separate from

mains wiring to minimise noise pick up.

Set within Engineers functions for remote

sensor.

Low Voltage

+24V DC

(FAN CIRCUIT)

Volt free

Fan Trip

Indication

by others

Note: Connection to the

burners MUST be made

via a 3A fused spur.

(COMMON)

(REMOTE OFF)

eg Door

Remote OFF

(where applicable)

Remote ON

(where applicable)

eg B.M.S.

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

41 40 7 8 14 5 6C 9 25

NEUT

LIVE

Black

Bulb

Sensor

(REMOTE ON)

0-10VDC

Modulating

( MODULATING 0-10VDC)

(0V)

FAN MOTOR

230V 3-Phase Supply.

Motor must be wired

DELTA

Exhaust

Fan

To other slave

controllers

where app.

C2 C0 C1

Supply to inline

burners

Burners

Zone A

SmartCom Mulitizone

(Master if networked)

THE LOCAL RELAY UNIT

houses

an inverter.The inverter provides

a soft start to the motor, which

extends the motor life by

minimising the start current.

IMPORTANT

For Inverter panels only MAXIMUM length of cable

between inverter and fan is 5m (EMC class A building)

or 10m (EMC class B building).

N.B. if in doubt, do not exceed 5m.

SUPPLY VIA ISOLATOR

ELECTRICAL INPUT

415V 3P 25A

FAN TYPE

BH300

Inverter Local Relay Unit

E E

L1 L1 N N

V W 1 2

5 6

Figure 4.p. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 via three phase inverter panel. (single zone shown)

Page 23

Doc No. 700070 Page 23 of 56

Supply via Isolator

230V 50Hz 1 Pha

Burners

Zone A

Drawing No. : 900289 MOD DAMP R9

Supply to inline

burners

4-Core Armoured cable

FAN MOTOR

415V 3-Phase Supply.

Motor must be wired

DELTA

3 Phase

Isolator

(HEAT 1 OUTPUT)

(LIVE)

(NEUTRAL)

NOTES:

REMOTE SWITCH INPUTS

should be connected by 6A mains Max

length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to enable).

Connect to B0 & B1 for remote ON (ie

BMS time control).

Connect to B0 & B2 for remote OFF (ie

door interlock. remote frost etc).

*The power supply is non-isolated, therefore all

wiring to the control must be mains rated.

REMOTE SENSOR(s) may be placed at

a max distance of 100m from the control

unit, using screened 6A mains* cable.

Wiring should be kept separate from

mains wiring to minimise noise pick up.

Set within Engineers functions for remote

sensor.

*The power supply is non-isolated, therefore all

wiring to the control must be mains rated.

Mains Voltage

230V AC

(FAN CIRCUIT)

Volt free

Fan Trip

Indication

by others

Note: Connection to the

burners MUST be made

via a 3A fused spur.

(COMMON)

(REMOTE OFF)

eg Door

Remote OFF

(where applicable)

Remote ON

(where applicable)

eg B.M.S.

SmartCom Mulitizone

(Master if networked)

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

41 40 7 8 14 5 6C 9 25

NEUT

LIVE

Black

Bulb

Sensor

(REMOTE ON)

0-10VDC

Modulating

( MODULATING 0-10VDC)

(0V)

Modulating

Dampers

To other slave

controllers

where app.

Exhaust

Fan

C2 C0 C1

SUPPLY VIA ISOLATOR

ELECTRICAL INPUT

415V 3P 25A

FAN TYPE

BH300

THE LOCAL RELAY UNIT

houses a 3pha motor contactor

and overload plus any additional

fan logic circuitry.

Local Relay Unit

E E L1 L1 N N

V W 1 2

5 6

Figure 4.r. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 and zonal branch dampers via three phase LRU panel. (1 zone shown)

Page 24

Doc No. 700070 Page 24 of 56

Supply via Isolator

230V 50Hz 1 Pha

Drawing No. : 900289 MOD FAN R9

4-Core Armoured or

Screened Cable 1.5mm

3 Phase

Isolator

(HEAT 1 OUTPUT)

(LIVE)

(NEUTRAL)

NOTES:

REMOTE SWITCH INPUTS

should be connected by 6A mains

Max length is 100m.

Low voltage switching inputs to be

normally open (closed circuit to

enable).

Connect to B0 & B1 for remote ON (ie

BMS time control).

Connect to B0 & B2 for remote OFF

(ie door interlock. remote frost etc).

*The power supply is non-isolated, therefore

all wiring to the control must be mains rated.

REMOTE SENSOR(s) may be placed

at a max distance of 100m from the

control unit, using screened 6A

mains* cable.

Wiring should be kept separate from

mains wiring to minimise noise pick

up. Set within Engineers functions for

remote sensor.

*The power supply is non-isolated, therefore

all wiring to the control must be mains rated.

Mains Voltage

230V AC

(FAN CIRCUIT)

Volt free

Fan Trip

Indication

by others

Note: Connection to the

burners MUST be made

via a 3A fused spur.

(COMMON)

(REMOTE OFF)

eg Door

Remote OFF

(where applicable)

Remote ON

(where applicable)

eg B.M.S.

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

41 40 7 8 14 5 6C 9 25

NEUT

LIVE

Black

Bulb

Sensor

(REMOTE ON)

( MODULATING 0-10VDC)

(0V)

FAN MOTOR

415V 3-Phase Supply.

Motor must be wired

DELTA

Exhaust

Fan

To other slave

controllers

where app.

C2 C0 C1

Supply to inline

burners

Burners

Zone A

SmartCom Mulitizone

(Master if networked)

0-10VDC

Modulating

Damper

SUPPLY VIA ISOLATOR

ELECTRICAL INPUT

415V 3P 25A

FAN TYPE

BH300

THE LOCAL RELAY UNIT

houses a 3pha motor contactor

and overload plus any additional

fan logic circuitry.

Local Relay Unit

E E L1 L1

N N

V W

1 2

5 6

Figure 4.s. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 and fan damper via three phase LRU panel. (1 zone shown)

Page 25

Doc No. 700070 Page 25 of 56

Figure 4.t. Additional wiring for NRV M individual burner lockout

(HEAT 1 OUTPUT)

(COMMON)

(REMOTE ON)

(REMOTE OFF)

Burners Zone A

Volt Free

BMS

230V VBurner ON Signal

Circuit

Volt Free Remote ON

THE SOFTWARE FOR THE BMS MUST ONLY REQUEST A LOCKOUT CONDITION WHEN THE SYSTEM IS REQUESTING HEAT. IN ADDITION, IT SHOULD ALSO PROVIDE A 60s DELAY BEFORE INDICATING LOCKOUT. THIS IS TO ALLOW THE SOLENOID COIL TO OPERATE AFTER INITIAL SUPPLY IS CONNECTED TO THE HEATER, WHEN CALLING FOR THE HEAT VIA THE CONTROL SYSTEM AND A RE-START ATTEMPT IF NECCESARY. Note: If the point is not complied with the BMS will receive a false report of the burner status.

Circuit Burner #1

Volt Free Burner Lockout

Volt Free Fan Trip Circuit

Circuit Burner #2

Volt Free Burner Lockout

Circuit Burner #3

Volt Free Burner Lockout

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

5 6

NEUT

LIVE

SmartCom Mulitizone

Volt Free

To Other Burners

Volt Free Burner Lockout

Mains Voltage

Volt Free

Drawing No. : 900287 R9 MOD LOM

THE LOCKOUT WIRING SHOULD

BE SUCH THAT IF THAT PARTICULAR BURNER

WERE TO LOCKOUT, THE WIRING CIRCUIT WILL EITHER MAKE

OR BREAK DEPENDENT ON THE REQUIREMENT OF THE BMS.

Inverter Local Relay Unit

N N

V W 1 234

5 6

Drawing No. : 900287 R9 MOD LO

(HEAT 1 OUTPUT)

(COMMON)

(REMOTE ON)

(REMOTE OFF)

Burners

Zone A

Volt

Free

BMS

230V VBurner ON Signal

Circuit

Volt Free Remote ON

Circuit Zone 1

Volt Free Burner Lockout

Volt Free Fan Trip Circuit

! FUSE RATING

1/L 2/N 10

S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20

5 6

NEUT

LIVE

SmartCom Mulitizone

Volt Free

Lockout To

Volt Free Burner

Mains Voltage

Volt

Free

Other Zones

(if required)

THE LOCKOUT WIRING SHOULD

BE SUCH THAT IF ANY OF THE BURNERS

IN THE NETWORK WERE TO LOCKOUT, THE

WIRING CIRCUIT WILL EITHER MAKE OR BREAK

DEPENDENT ON THE REQUIREMENT OF THE BMS.

Inverter Local Relay Unit

N N

V W 1 234

5 6

Figure 4.v. Additional wiring for NRV M zonal burner lockout

Page 26

Doc No. 700070 Page 26 of 56

1.12 Ventilation Requirements

Nor-Ray-Vac heaters are installed as ued appliances in accordance with the relevant national requirements in the country of installation.

In buildings having an air change rate of less than 0.5 per hour, additional ventilation is required. For detailed information, please see BS6896 section 5.2.2.2.1

Natural Ventilation Low level ventilation openings with a free area of at least

2cm²/kW shall be provided. See BS6896 section 5.2.2.2.2.1.

1.13 Exhaust and Air Inlet - Options

g5.a. Horizontal discharge

Considerations.

The vacuum fan must be located as shown in the layout drawing.

The vacuum fan must have a bottom horizontal discharge.

The fan should be tted to the mounting platform which is xed to the wall or building structure. Alternatively, the fan can be suspended from the roof structure, via drop rods (not supplied) and mounted on base frame. (Anti-vibration mountings are tted between the fan and the mounting platform/base frame).

For full details of parts and installation, please refer to Booklet 2, Document Ref 700071

g5.b. Vertical discharge

Page 27

Doc No. 700070 Page 27 of 56

g 5.d. End Vent Ducted Air Inlet Connection

g 5.c. Header Duct Connection

g 5.e. Burner Ducted Air Inlet Connection

Branch Duct Ø100 for NRV 24M, Ø100 for NRV 32M-46M

Main Header Duct Ø150 for NRV 24M, Ø100 for NRV 32M- 46M

Ø100 Duct to EVM

Ø100 Duct to Burner

500mm MIN

450mm MIN

(for header duct

directly above system)

1.13.1 Ducted Air Inlet Considerations.

Heat resistant exible tube is connected to the burner

assembly ducted air adaptor and the EVM ducted air

adaptor and connected to the air supply duct

The maximum length of 100mm diameter ductwork is

2m.

Ensure that the exible supply duct does not drape

over or touch the reector.

ensure that the exible ductwork is installed to allow for expansion of the heating system.

On a header duct, the main air supply header which is feeding the individual branch ducts and burner/end vent supply ducts must have a maximum pressure drop of 0.25 mbar (0.1in wg).

All joints and seams in the air supply system must be made air tight and a bird screen used at the inlet.

Page 28

Doc No. 700070 Page 28 of 56

1.14 Vacuum fan mounting details (Type ‘B160’ fan illustrated)

Fan Size B80 B160 B300 BH300

A (crs) 216 276 286 324

B 595 595 625 704

C 305 308 330 352

D 580 555 575 650

E (Ø) 150 152 152 152

F 50 97 50 50

G (Ø) 150 150 150 148

H 295 318 340 380

J 80 90 90 110

K 150 140 140 120

L 240 240 240 240

M 309 303 341 404

N 50 62 157 157

P 421 463 616 680

R (crs) 318 318 318 318

S (crs) 356 356 3596 356

T 204 204 204 204

V 115 115 115 115

Z 21 36 46 84

Page 29

Doc No. 700070 Page 29 of 56

Burner type 24M 32M 38M 46M

Burner details

G20 Natural Gas

Gas category ii Heat input (Gross) 100% rate Nat Gas G20 kW 24 32 38 46 Heat input (Gross) 50% rate Nat Gas G20 kW 12 16 19 23 Gas consumption 100% rate Nat Gas G20 m³/ h 2.29 3.05 3.62 4.38 Gas consumption 50% rate Nat Gas G20 m³/ h 1.15 1.53 1.81 2.19 Max Inlet pressure Nat Gas G20 mbar 50 50 50 50 Min Inlet Pressure Nat Gas G20 mbar 17. 5 17. 5 17. 5 17. 5 Hs Nat Gas G20 MJ/m³ 37.78 37.78 37. 78 37.78 Hi Nat Gas G20 MJ/m³ 34.02 34.02 34.02 34.02 d Nat Gas G20 0.556 0.556 0.556 0.556 Ws Nat Gas G20 MJ/m³ 50.72 50.72 50.72 50.72 Wi Nat Gas G20 MJ/m³ 45.67 45.67 45.67 45.67 Injector size Nat Gas G20 mm 4.9 5.4 5.8 6.3 Injector Part No. L10 0549 L10 055 4 L100 558 L100 563 Air shutter size Nat Gas G20 mm 19.5 22 24 26.5 Air shutter Part No. L10 0320 L10 0314 L10 0316 L10 0318

G31 Propane

Gas category iii Heat input (Gross) 100% rate Propane G31 kW 24 32 38 46 Heat input (Gross) 50% rate Propane G31 kW 12 16 19 23 Gas consumption 100% rate Propane G31 m³/h 0.90 1.21 1.43 1.73 Gas consumption 50% rate Propane G31 m³/h 0.45 0.61 0.72 0.86 Max Inlet pressure Propane G31 mbar 57. 5 57. 5 57. 5 57. 5 Min Inlet Pressure Propane G31 mbar 25 25 25 25 Hs Propane G31 MJ/m³ 95.65 95.65 95.65 95.65 Hi Propane G31 MJ/m³ 88.00 88.00 88.00 88.00 d Propane G31 1.55 1.55 1.55 1.55 Ws Propane G31 MJ/m³ 76.84 76.84 76.84 76.84 Wi Propane G31 MJ/m³ 70.69 70.69 70.69 70.69 Injector size Propane G31 mm 4.0 4.4 4.8 5.2 Injector Part No. L10 0540 L10 054 4 L10 0548 L10 0552 Air shutter size Propane G31 mm 19.5 22 24 26.5 Air shutter Part No. L10 0320 L10 0314 L10 0316 L10 0318

No of Injectors 1 Gas Connection ½ in BSP Internal thread Burner current 0.05 (per burner) Electrical Voltage/Ph/Hz 230 volt 1 phase 50Hz

1.15 Technical Details.

Tables 4a & b Burner Details

Page 30

Doc No. 700070 Page 30 of 56

Burner type 24M 32M 38M 46M

Min distance between burners m 9.4 14 18 23

Max distance between burners m 13.1 18 23 27

Min distance between burner and tting m 5.0 6.0 7.0 8.0

Max tube temp °C 450 480 480 480

Min mounting height m 4.0 4.7 5.3 6.0

Max burners per branch 3 3 3 3

Table 5. Heater Details

Burner type 24M 32M 38M 46M

Noise level @ 3m below

In-Line BURNER

db(A) 37 tba tba tba

NR±2 33 tba tba tba

Noise level @ 3m below

EVM Burner

db(A) tba tba tba tba

NR±2 tba tba tba tba

Noise level @ 3m below EVM with silencer

db(A) tba 36 tba tba

NR±2 tba 33 tba tba

Noise level @ 3m below

EVM Burner with Ducted Air

db(A) tba 37 tba tba

NR±2 tba 34 tba tba

Table 6. Heater Noise

Burner type 24M 32M 38M 46M

LR Burner kg 8.3 8.3 8.3 8.3

Radiant branch* kg/m 8.3 8.3 8.3 8.3

Radiant branch + Slimline grille* kg/m 10.9 10.9 10.9 10.9

Radiant branch + Protective guard* kg/m 10.0 10.0 10.0 10.0

4” Mild steel tail pipe kg/m 5.5 5.5 5.5 5.5

4” Aluminum tail pipe kg/m 0.9 0.9 0.9 0.9

6” Mild steel tail pipe kg/m 10.6 10.6 10.6 10.6

6” Aluminium tail pipe kg/m 1.3 1.3 1.3 1.3

Max / susp point @ EV position kg 24.2 24.2 24.2 24.2

Table 7. System Weights * without burners or ducted air systems

Page 31

Doc No. 700070 Page 31 of 56

Table 8. Fan Details

Fan type B80 B160 B300 BH300

Noise level @ 3m below fan

db(A) 63 64 65 68 NR±2 57 58 59 62

Noise level @ 3m below fan

with motor mu

db(A) 62 63 64 66 NR±2 56 57 58 60

Noise level @ 3m below in acoustic enclosure

db(A) 51 53 55 58 NR±2 45 47 49 52

Flue horizontal/vertical @ 3m

db(A) 69 72 75 77 NR±2 63 66 69 71

Flue horizontal/vertical @ 3m

With exhaust silencer

db(A) 56 57 58 58 NR±2 50 61 52 52

Table 10. Fan Noise Data

Fan type B80 B160 B300 BH300

Fan part number 201760 201761 201762 201763

Motor (TEE)

Q2E80M2D-KG-H Q2E90L2C-KG-H Q2E90L2D-KG-H Q2E112M2C-KG-H

Power kW 1.1 1.5 2.2 4.0

Supply to Fan V/Hz/P 230-50/3 230-50/3 230-50/3 415-50/3

Run Current A 4.24 5.6 8.14 7.7

Start Current A n/a n/a n/a 54

Speed RPM 2850 2860 2840 2880

Wired Inverter ∆ ∆ ∆ ∆

D.O.L. ∆

Flow rate @ 20°C m³/ h 368 736 1380 1380

Flow rate @ 150°C m³/ h 259 519 972 972

Pressure mbar 29 29 29 42

Max Operating Temp. °C 200 200 200 200

Weight kg 45 52 58 75

Table 9. LRU Details

Fan type B80 B160 B300 BH300

LRU part number 900274 900088 900089 900632 900282

Inverter type kW 1.5 1. 5 2.2 4.0 STD LRU

Supply to LRU V/Hz/P 230-50/1 230-50/1 230-50/1 415-50/3 415-50/3

Line Current A 14.8 14.8 20.8 15 n/a

Motor Current A 4.24 5.6 8.14 7.7 7. 7

Fuse Rating A 22 22 30 25 n/a

Acceleration Time s 25 25 25 25 n/a

Deceleration Time

25 25 25

25 n/a

Page 32

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3. Commissioning Instructions.



These appliances should be commissioned by a

qualied engineer. 

3.1 Tools Required.

 The following tools and equipment are advisable to

complete the tasks laid out in this manual. 

Suitable alternative tools may be used.

3.2 General

Under normal working conditions it is recommended

that the Nor-Ray-Vac ‘M’ series system is regularly maintained to ensure long life and ecient operation.

Maintenance is required only once per year.

In dusty or dirty conditions more frequent maintenance is desirable. Servicing work must be carried out by a qualied gas service engineer.

Important

When maintaining or servicing the Nor-Ray-Vac ‘M’ series systems:

• Never rest anything, especially ladders against heating system.

• Isolate gas and electrical supplies before commencing any service work.

Leather Faced

Gloves

Various Flat Head

Screwdrivers

Various Pozidrive

Screwdrivers

Allen Key set Adjustable Spanner

or 22, 26 & 27mm

Spanners

Manometer

3.3 Commissioning Procedure

3.3.1 Start Up Checks

3.3.1.1 Check that the installation is to the design layout drawing and installed in accordance with the installation instructions.

3.3.1.2 Check installation electrically. Ensure that the vacuum fan, inverter, burners and control panel are wired correctly to diagrams provided.

3.3.1.3 Ensure that each burner is electrically disconnected at the plug/socket.

3.3.1.4 Set individual burner delay timer dip-switches (located in each burner) to required setting.

Refer to section 3.3.1.8

3.3.1.5 With the gas turned on, check the burner inlet pressure.

The gas pressure at the burner inlet connection must

not exceed:

50 mbar (20in wg) for Natural Gas G20 and 57.5 mbar (23in wg) for G31 Propane Gas.

3.3.1.6 Start the vacuum fan.

Note For various controllers/BMS systems it may be

necessary to adjust the set point to above room temperature.

For fans with an inverter panel, check that the display

states “rdy” (ready).

3.3.1.7 Check for correct fan rotation.

3.3.1.8 Adjust the vacuum setting.

INJECTOR PRESSURE

TEST POINT

GAS INLET

TEST POINT

ADJUSTMENT SCREW UNDER

CAP TO SET INJECTOR PRESSURE

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3.3.1.9 Burner Timer Dip-switch Adjustment

Each burner is tted with an adjustable burner delay timer. The timer is adjusted using dip-switches located on top of the timer casing.

The dip-switches are labeled 1, 2, 3 and 4. These numbers correspond to the burner positions within the radiant branch.

The burner located nearest to the exhaust fan in that branch is noted as Burner 1, this is the case irrespective of how

many other burners are in that branch.

The burner directly behind burner 1 is always noted as Burner 2, the burner directly behind

Burner 2 is Burner 3 and so on nishing at the End Vent Burner.

Set the burner timer dip-switch.

For example, the timer on burner 1 is set by sliding the white

dip-switch, positioned above the number 1, towards

the number. The timer on burner 2 is set by sliding

the white dip-switch, positioned above the

number 2, towards the number.

Table 11. Quantity of

burners

in-line

Individual Dip-switch position

*1 *2 *3 *4 *5

2 1 2

3 1 2 3

4 1 2 3 4

5 1 1 2 3 4

To set dip-switch slide the white switch toward the numbers (1 - 4)

*Burner number within each radiant branch - lowest number closest to fan

End Vent - BURNER 4

dip switch settings

In-Line - BURNER 3

dip switch settings

In-Line - BURNER 2

dip switch settings

In-Line -

BURNER 1

dip switch

settings

Page 34

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The end vent vacuum is measured by removing the protection cap on the tee piece in the air impulse line on the end vent burner and connecting a manometer.

3.4 Inverter Driven Modulating Fans (B80, B160, B300 with Schneider inverter)

The use of an inverter allows the end vent suction to be adjusted by varying the output speed of the inverter within the local relay unit. This is achieved via a 0-10Vdc input direct to the inverter via an external control.

NOTE: Ensure the modulation input setting in the inverter functions has been adjusted accordingly.

3.4.1 Press the mode button 3 times until ‘ConF’ appears on the display.

3.4.2 Press the jog dial to enter. Rotate jog dial until ‘A I It’ is displayed. Press jog dial to enter.

3.4.3 Rotate jog dial until ‘IOU’ is displayed. Press jog dial to enter, causing the inverter to accept 0-10Vdc.

3.4.4 Ensure that electrical supply to the end vent modules and burners in each branch are connected.

3.4.5 Check that the fan and branch dampers are fully open and secure.

3.4.6 Ensure the controller is in a programmed ON function and above the actual room temperature.

3.4.7 After a 30s delay the fan should run and the inverter should be showing the motor frequency in the display.

3.4.8 Press the mode button 3 times until ‘ConF’ appears on the display.

3.4.9 Press the jog dial to enter. Rotate jog dial until ‘HSP’ is displayed. Press jog dial to enter.

3.4.10 Rotate jog dial to adjust frequency. Press jog dial to enter new value, causing the inverter to change its speed.

3.4.11 Adjust the frequency until each burner has lit.

Frequency is usually between 35 and 50 (Hz)

3.4.12 Press the ESC button twice to return the inverter to the ’rdY’ display.

3.4.13 Remove heat demand from the system and allow fan to halt.

3.4.14 Return heat demand to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.4.15 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite rst followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

3.4.16 Observe the ignition of ALL the burners. An amber neon should illuminate on the rear of the burner when the burner is lighting and remain if the burner has lit. If the burner fails to light, the amber neon will extinguish leaving only the red neon illuminated.

3.4.17 When the branch has been running for 30 minutes, check the end vent vacuum reading at the burner FU R T H E ST AWAY.

Re-adjust the frequency on the inverter as follows:

3.4.18 Press the mode button 3 times until ‘ConF’ appears on the display. Press the jog dial to enter.

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3.4.19 Rotate jog dial until ‘HSP’ is displayed. Press jog dial to enter.

3.4.20 Rotate jog dial to adjust the frequency on the inverter until the high re end vent suction is achieved (details of which are given in table 12). Press jog dial to enter new value.

3.4.21 Remove heat demand from system.

3.4.22 Rotate jog dial until ‘LSP’ is displayed. Press jog dial to enter.

3.4.23 Rotate jog dial to adjust the frequency on the inverter until the low re end vent suction is achieved.

3.4.24 Return heat demand to system.

3.4.25 Proceed to the next radiant branch closer to the fan and check the end vent vacuum reading at high and low re.

3.4.26 Adjust the branch damper (if necessary) located at the end of the branch to bring the vacuum readings in line with the normal operating gure shown in table 12. Ensure the damper is locked securely after adjustment.

Adjustment instruction for branch damper.

1. Loosen grub screw (A).

2. Turn adjustment lever (B).

3. Position of damper blade is indicated by position of bent adjustment lever.

4. Tighten grub screw (A) to secure damper position.

3.4.27 Repeat procedure 3.4.26 for any further branches (where necessary), moving closer to the fan as each branch is completed.

The vacuum setting procedure is now complete.

3.5 Schneider Inverter Driven B80, B160, B300 Fan, Modulating Branch Damper (Zonal modulation)

In this method, the fan is driven by the inverter and adjusted to give the correct output for full re.

Modulation is achieved by adjusting each branch damper via a 0-10Vdc input to the damper motor via an external control.

3.5.1 Ensure that electrical supplies to the end vent modules and burners in each branch are connected.

3.5.2 Check that the fan and branch dampers are fully open and secure.

3.5.3 Ensure the controller is in a programmed ON function and above the actual room temperature.

3.5.4 After a 30s delay the fan should run and the inverter should be showing the motor frequency in the display.

3.5.5 Press the mode button 3 times until ‘ConF’ appears on the display.

3.5.6 Press the jog dial to enter. Rotate jog dial until ‘LSP’ is displayed. Press jog dial to enter.

3.5.7 Rotate jog dial to adjust frequency. Press jog dial to enter new value, causing the inverter to change its speed.

3.5.8 Adjust the frequency until each burner has lit.

Frequency is usually between 35 and 50 (Hz)

3.5.9 Press the ESC button twice to return the inverter to the ’rdY’ display.

3.5.10 Remove power to the system and allow fan to halt.

3.5.11 Return power to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.5.12 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite rst followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

FOLLOW INSTRUCTIONS ON P39 (3.8) FROM THIS POINT

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3.6 Inverter Driven Modulating Fans ( BH300 with ABB inverter)

NOTE: Ensure the modulation input setting in the inverter functions has been adjusted accordingly.

3.6.1 Ensure that electrical supplies to the end vent modules and burners in each branch are connected.

3.6.2 Check that the fan and branch dampers are fully open and secure.

3.6.3 Ensure the controller is in a programmed ON function and set to maximum temperature. (10V dc max from the controller).

3.6.4 After a 30s delay the fan should run and the inverter should be showing the motor frequency in the display.

3.6.5 Set the maximum motor speed parameter 2008 to a Hz value where all the burners light reliably.

Frequency is usually between 35 and 50 (Hz)

3.6.6 Press the ‘ ‘ button to return the inverter to the normal display.

3.6.7 Remove heat demand from the system and allow fan to halt.

3.6.8 Return heat demand to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.6.9 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite rst followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

3.6.10 Observe the ignition of ALL the burners. An amber neon should illuminate on the rear of the burner when the burner is lighting and remain if the burner has lit. If the burner fails to light, the amber neon will extinguish leaveing only the red neon illuminated.

3.6.11 When the branch has been running for 30 minutes, check the end vent vacuum reading at the burner

Menu selection (also save/OK ‘ ‘ and

exit ‘ ‘)

Parameter selection

FU R T H E ST AWAY.

3.6.10 Re-adjust the frequency on the inverter (parameter

2008) until the high re end vent suction is achieved (details of which are given in table 12)

3.6.11 Remove heat demand from controller.

3.6.12 Set the minimum motor speed parameter 2007 to adjust the frequency until the low re end vent suction is achieved (details of which are given in table 12).

3.6.13 Reset controller to give heat demand.

3.6.14 Proceed to the next radiant branch closer to the fan and check the end vent vacuum reading at high and low re.

3.6.15 Adjust the branch damper (if necessary) located at the end of the branch to bring the vacuum readings in line with the normal operating gure shown in table 12. Ensure the damper is locked securely after adjustment.

Adjustment instruction for branch damper.

1. Loosen grub screw (A).

2. Turn adjustment lever (B).

3. Position of damper blade is indicated by position of bent adjustment lever.

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4. Tighten grub screw (A) to secure damper position.

3.6.16 Repeat procedure 3.6.14 for any further branches (where necessary), moving closer to the fan as each branch is completed. The vacuum setting procedure is now complete.

3.7 ABB Inverter Driven BH300 Fan, Modulating Branch Damper (Zonal modulation)

In this method, the fan is driven by the inverter and adjusted to give the correct output for full re.

Modulation is achieved by adjusting each branch damper via a 0-10Vdc input to the damper motor via an external control.

3.7.1 Ensure that electrical supplies to the end vent modules and burners in each branch are connected.

3.7.2 Check that the fan and branch dampers are fully open and secure.

3.7.3 Ensure the controller is in a programmed ON function and above the actual room temperature.

3.7.4 After a 30s delay the fan should run and the inverter should be showing the motor frequency in the display.

3.7.5 Set the maximum motor speed parameter 2008 to a value where all the burners light.

Frequency is usually between 35 and 50 (Hz)

3.7.6 Press the ‘ ‘ button to return the inverter to the normal display.

3.7.7 Remove heat demand to the system and allow fan to halt.

3.7. Return power to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.7.6 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite rst followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

FOLLOW INSTRUCTIONS ON P39 (3.8) FROM THIS POINT

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3.8

3.8.1 Observe the ignition of ALL the burners. An amber neon should illuminate on the rear of the burner when the burner is lighting and remain if the burner has lit. If the burner fails to light, the amber neon will extinguish leaving only the red neon illuminated.

3.8.2 When the branch has been running for 30 minutes, remove the 0-10v signal from the damper and check the end vent vacuum reading at the burner FURTHEST AWAY.

3.8.3 Adjust the branch damper by engaging the manual overide and rotating the damper spindle until the high re end vent suction is achieved (details of which are given in table 12). Once the high re is set, lock the maximum stop in place.

3.8.4 Adjust the branch damper again until the low re end vent suction is achieved (details of which are given in table

12). Once the low re is set, lock the minimum stop in place.

Modulation adjustment instruction for branch damper.

1. Engage manual overide by pushing in black button (A).

2. Rotate spindle to achieve correct suction (B).

3. Lock stop in place (C) to secure damper position.

4. Repeat for low re. Min stop not shown in photo

5. Check correct rotation is selected (D)

3.8.5 Proceed to the next radiant branch closer to the fan and commission in the same manner, observing the ignition sequence of the burners and amber neon’s.

3.8.6 Check the end vent vacuum readings, adjusting where neccessary.

3.8.7 Repeat procedure above for any further branches (where necessary), moving closer to the fan as each branch is completed.

3.8.8 Re-connect the 0-10Vdc input to the dampers. The vacuum setting procedure is now complete.

3.9 Non-Inverter Driven Fans, Modulating Branch Damper (Zonal modulation)

(fans controlled by NRV ‘logic’ driven LRU’s with no inverter)

End vent vacuum settings are made rstly by means of adjusting the damper at the vacuum fan inlet, this brings the end vent with the lowest reading to the normal operating vacuum.

Modulation is achieved by adjusting each branch damper via a 0-10Vdc input to the damper motor via an external control.

Ensure that all dampers are locked after adjustment.

Ensure that each burner is electrically disconnected at the end vent module plug/socket.

3.9.1 Check vacuum fan inlet and branch dampers are fully open in the rst instance and secure.

3.9.2 Ensure the controller is in a programmed ON and above the actual room temperature.

3.9.3 After a 30s delay the fan should run.

3.9.4 Working at the end vent burner FURTHEST AWAY from the fan, measure the vacuum pressure and adjust the fan inlet damper to obtain over 8.7 - 10 mbar (above 3.6in wg) WHEN COLD.

3.9.5 Remove heat demand from the system and allow fan to halt.

3.9.6 Ensure that each burner is electrically re-connected at the end vent module plug/socket.

3.9.7 Return heat demand to system. After a 30s delay the fan should run and a red neon should have illuminated on the rear of each burner.

3.9.8 If the dip-switches have been set correctly, the burner closest to the manifold (last on branch) should ignite rst followed in order by every burner towards the end vent burner.

Note: It may be necessary to temporarily break the union at a burner in order to purge the gas pipe of air.

3.9.9 Observe the ignition of ALL the burners. An amber neon should illuminate on the rear of the burner when the burner is lighting and remain if the burner has lit. If the burner fails to light, the amber neon will extinguish leaving only the red neon illuminated.

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3.9.10 When the branch has been running for 30 minutes, disconnect the 0-10V input to the dampers and check the end vent vacuum reading at the burner FURTHEST AWAY.

3.9.11 Adjust the branch damper by engaging the manual overide and rotating the damper spindle until the high re end vent suction is achieved (details of which are given in table 12). Once the high re is set, lock the maximum stop in place.

3.9.12 Adjust the branch damper again until the low re end vent suction is achieved (details of which are given in table

12). Once the low re is set, lock the minimum stop in place.

Modulation adjustment instruction for branch damper.

1. Engage manual overide by pushing in black button (A).

2. Rotate spindle to achieve correct suction (B).

3. Lock stop in place (C) to secure damper position.

4. Repeat for low re. Min stop not shown in photo

5. Check correct rotation is selected (D)

3.9.13 Proceed to the next radiant branch closer to the fan and commission in the same manner, observing the ignition sequence of the burners and amber neon’s.

3.9.14 Check the end vent vacuum readings, adjusting where neccessary.

3.9.15 Repeat procedure above for any further branches (where necessary), moving closer to the fan as each branch is completed.

3.9.16 Re-connect the 0-10Vdc input to the dampers. The vacuum setting procedure is now complete.

3.10 Non-Inverter Driven Fans, Modulating Fan Damper (System modulation)

(fans controlled by NRV ‘logic’ driven LRU’s with no inverter)

End vent vacuum settings are made rstly by means of adjusting the damper at the vacuum fan inlet, this brings the end vent with the lowest reading to the normal operating vacuum.

Modulation is then achieved by adjusting this damper via a 0-10Vdc input to the damper motor via an external control.

Ensure that all dampers are locked after adjustment.

Ensure that each burner is electrically disconnected at the end vent module plug/socket.

3.10.1 Check vacuum fan inlet and branch dampers are fully open in the rst instance and secure.

3.10.2 Ensure the controller is in a programmed ON and above the actual room temperature.

3.10.3 After a 30s delay the fan should run. disconnect the 0-10V input to the panel.

3.10.4 Working at the end vent burner FURTHEST AWAY from the fan, measure the vacuum pressure and adjust the fan inlet damper by engaging the manual overide and rotating the damper spindle until the high re end vent suction is achieved (details of which are given in the following table). Once the high re is set, lock the maximum stop in place.

3.10.5 Adjust the fan inlet damper again until the low re end vent suction is achieved (details of which are given in table 12). Once the low re is set, lock the minimum stop in place.

Modulation adjustment instruction for branch damper.

1. Engage manual overide by pushing in black button (A).

2. Rotate spindle to achieve correct suction (B).

3. Lock stop in place (C) to secure damper position.

4. Repeat for low re. Min stop not shown in photo.

5. Check correct rotation is selected (D)

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3.10.6 Proceed to the next radiant branch closer to the fan and check the end vent vacuum reading.

3.10.7 Adjust the branch damper (if necessary) located at the end of the branch to bring the vacuum readings in line with the normal operating gure shown in the chart. Ensure the damper is locked securely after adjustment.

Adjustment instruction for branch damper.

1. Loosen grub screw (A).

2. Turn adjustment lever (B).

3. Position of damper blade is indicated by position of bent adjustment lever.

4. Tighten grub screw (A) to secure damper position.

3.10.8 Repeat for any further branches (where necessary), moving closer to the fan as each branch is completed.

3.10.9 Re-connect the 0-10Vdc input to the dampers. The vacuum setting procedure is now complete.

3.11 Final Commissioning.

3.11.1 Check that the burner injector pressures are ZERO ±

0.25 mbar (±0.1in wg). Adjust if necessary.

3.11.2 Check operation of thermostat controllers a number of times, allowing the burner ignition cycle to complete each time, checking that each burner relights.

3.11.3 With all burners ring check the inlet gas pressure at the burner furthest away from the gas supply. The min inlet pressure is 17.5mbar for G20 (Nat Gas), and 25mbar for G31 (Propane). The dierence between gas pressure at the burner, with all the burners on and all the burners o should not be more than 2.5 mbar (1in wg).

3.11.4 Take gas consumption meter readings for each separate NRV system or building heated ensuring all other loads are o.

3.11.5 After the system has reached equilibrium: take the following measurements:

a. The ue gas temperatures entering the vacuum fan. The ue gas sample point located on the vacuum fan tee is used.

b. The surface temperature of the underside of the tube at the end of each radiant branch.

c. The surface temperature of the underside of the tube at a point directly underneath each combustion chamber suspension lug.

3.11.6 With the system running, check that under all possible congurations of normal operation, the system functions in accordance with these instructions.

3.11.7 Reset thermostat controllers to required setting.

3.11.8 Complete service report sheet.

INJECTOR PRESSURE

TEST POINT

ADJUSTMENT SCREW UNDER

CAP TO SET INJECTOR PRESSURE

Table 12.

Equivalent burner kW rating

End Vent Suction/

Burner type mbar HOT 24M 32M 38M 46M

@ HIGH re rate 100% 6.25 mbar 23.0kW 32.0kW 38.0kW 46.0kW @ 90% Low re rate* 5.6 mbar 21.6kW 28.8kW 34.2kW 41.4kW @ 80% Low re rate* 4.3 mbar 19.2kW 25.6kW 30.4kW 36.8kW @ 70% Low re rate* 3.5 mbar 16.8kW 22.4kW 26.6kW 32.2kW @ 60% Low re rate* 2.4 mbar 14.4kW 19.2kW 22.8kW 27.6kW @ MINIMUM LOW re rate 50%* 1.5 mbar 12.0k W 16.0kW 19.0kW 23.0kW

* Note: Zonal modulation (individual branch damper systems) can have unique low re rate at the end vents from the list above (50% - 90%). Full system modulation can only have ONE low re rate from the above list for ALL end vents. In all cases, the high re rate must be 100%

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3.9.1 Typical Unequally Balanced System Layout Modulating controlled via single phase Inverter panel

Table 12. Equivalent burner kW rating

End Vent Suction mbar HOT

24M 32M 38M 46M

@ HIGH re rate 100% 6.25 mbar 23.0kW 32.0kW 38.0kW 46.0kW

@ 90% Low re rate* 5.6 mbar 21.6 kW 28.8kW 34.2kW 41.4 kW

@ 80% Low re rate* 4.3 mbar 19. 2kW 25.6kW 30.4kW 36.8kW

@ 70% Low re rate* 3.5 mbar 16. 8kW 22.4kW 26.6kW 32.2kW

@ 60% Low re rate* 2.4 mbar 14. 4kW 19.2k W 22.8kW 27.6kW

@ 50% Low re rate* 1.5 mbar 12.0k W 16.0kW 19. 0kW 23.0kW

* Full system modu lation can only have ONE low re rate fro m the above list for ALL end

vents. The hi gh re rate must be 100%

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3.9.2 Typical Unequally Balanced System Layout Modulating controlled via zonal branch dampers.

Table 12. Equivalent burner kW rating

End Vent Suction mbar HOT

24M 32M 38M 46M

@ HIGH re rate 100% 6.25 mbar 23.0kW 32.0kW 38.0kW 46.0kW

@ 90% Low re rate* 5.6 mbar 21. 6kW 28.8kW 34.2kW 41.4 kW

@ 80% Low re rate* 4.3 mbar 19.2kW 25.6kW 30.4kW 36.8kW

@ 70% Low re rate* 3.5 mbar 16 .8kW 22.4kW 26.6kW 32.2kW

@ 60% Low re rate* 2.4 mbar 14 .4kW 19.2kW 22.8kW 27.6kW

@ 50% Low re rate* 1.5 mbar 12 .0kW 16.0kW 19.0 kW 23.0kW

* Note: Zonal modu lation (individual bran ch damper systems) can have uniq ue low re rate

at the end vents fro m the list above (50% - 90%).

The high r e rate must be 100%

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Table 12. Equivalent burner kW rating

End Vent Suction mbar HOT

24M 32M 38M 46M

@ HIGH re rate 100% 6.25 mbar 23.0kW 32.0kW 38.0kW 46.0kW

@ 90% Low re rate* 5.6 mbar 21. 6kW 28.8kW 34.2kW 41. 4kW

@ 80% Low re rate* 4.3 mbar 19.2kW 25.6kW 30.4kW 36.8kW

@ 70% Low re rate* 3.5 mbar 16 .8kW 22.4kW 26.6kW 32.2kW

@ 60% Low re rate* 2.4 mbar 14 .4kW 19.2k W 22.8kW 27.6kW

@ 50% Low re rate* 1.5 mbar 12 .0kW 16 .0kW 19.0k W 23.0kW

* Full system modu lation can only have ONE low re rate fro m the above list

for ALL end vents. Th e high re rate must be 100%

3.9.3 Typical Unequally Balanced System Layout Modulating controlled via system fan damper .

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4. Servicing Instructions

These appliances should be serviced annually by a

competent person to ensure safe and ecient operation. In exceptional dusty or polluted conditions more frequent servicing may be required. The manufacturer oers a maintenance service. Details available on request.



4.1 Tools Required.

 The following tools and equipment are advisable to

complete the tasks laid out in this manual. 

Suitable alternative tools may be used.

4.2 Burner Exploded Views.

Figure 6.a. Burner Head

Leather Faced

Gloves

Various Flat Head

Screwdrivers

Various Pozidrive

Screwdrivers

Spanner Set

Wrench with

13mm Socket

Soft Brush

Allen Key Set Adjustable Spanner

or 22, 26 & 27mm

Spanners

Manometer

6 Burner head casting – L100103-SUB

7 Burner port insert – L100155

8 Flame retention grid – L100171 9 Air shutter plate - see selection chart

10 Burner jet - see selection chart

11 Electrode assembly – L100401

23 ½” plug – L100202

37 Set pin M4 x 6 – 5326-1

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Figure 6.b. LR Burner breakdown - EV shown

1 Control housing base plate – L102001 2 Control housing lid – L102009 3 Full sequence gas controller – 2015 4 Multi functional gas valve – C111513 plus 900041 5 Air lter – L102013 6 Burner head casting – L100103-SUB 7 Burner port insert – L100155 8 Flame retention grid – L100171 9 Air shutter plate - see selection chart 10 Burner jet - see selection chart 11 Electrode assembly – L100401 12 Mains input lter – 201292 Mains lead (not shown) – 2125 13 Air pressure switch (EV only) – 202861 14 Bulkhead compression tting (EV only) – 202861 15 Delay timer – L102025-SUB 16 Inline Socket (EV only) – 3123-5 Inline burner plug (EV only - not shown) – 3124 17 Wiring harness – E200067 18 Red neon light – 2180 19 Amber neon light – 2175 20 Gas inlet connection pipe ½” x 4” – 2360 21 Gas outlet inlet connection pipe 3/8” x 2½” – 2314-1 22 ½” x 3/8” reducing bush – 2320 23 ½” plug – L100202 24 Valve mounting bracket – L102020 25 Pressure switch bracket – L200025

26 Grommet (gas supply) – B200500 27 Grommet (13mm) – 2878 28 Burner gasket – L102032 29 Silicone gasket – L102031 30 Slide latch – L100200 31 Latch clip – L100201 32 Push clip – C110714 33 Wing nut – C111700 34 Set pin M4 x 12 – 5325 35 Set pin M4 x 10 – 5314 36 Set pin M5 x 10 – 5363 37 Set pin M4 x 6 – 5326-1 38 Washer M4 – 5322 39 Nut M4 – 5315 40 Torque Screw - 201093 41 Silicone tubing (EV only) – L100180-SUB 42 Silicone tubing (EV only) – L100181-SUB 43 Plastic tee (EV only) – L104200 44 Tee cap (EV only) – L104201 45 Three way solenoid air valve (option) - 2197 46 Lockout relay - (option) 2104 47 Lockout relay base - (option) 2108

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4.3 Vacuum fan

Inspect fan and ue ductwork for any contamination.

Inspect expansion joints for damage, replace if necessary.

4.4 Tubes

Inspect radiant tubes and ttings internally. If there is any appreciable build up of dust or deposits the tubes should be cleaned internally.

If corrosion is present replace as necessary.

Note It may be necessary to determine whether

chlorinated hydrocarbons are being used by the client.

4.5 Tube couplers

Check for tightness. Inspect for evidence of holes and cracks,

replace if necessary.

4.6 Reectors

Check for overlaps, re-adjust if necessary. The reectors may be cleaned with a soft

cloth and detergent in water.

4.7 Condensate trap

Inspect for dirt and scale, clean if necessary.

4.8 Igniter assembly (11)

Check ceramic visually for build up of carbon or cracks.

Check the spark distance and position of the electrodes relative to the burner head. Replace if necessary (see g.7).

4.9 Burner head (6)

Check condition of burner head insert and ame retention grid.

Replace if necessary.

4.10 Filter (5)

Replace if dirty.

4.11 Combustion Chamber Viewing Window

Window should be clean and free from cracks.

Replace if necessary.

4.12 Flue System

Flue needs to be inspected and cleaned if necessary.

Re-Commissioning system after servicing

(see section.3)

Figure 7.

Burner Electrode Details

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Item Description Part No.

Ignition Controller (3)* 2015

Gas Valve (4)* Twin Solenoid 220/240*

C111513

Valve Mini Harness 900041

Mains Inlet Socket (12) 201292

Igniter Assembly (11)* L10 04 01

Ignition HT Lead* 2243-1

Rectication Lead* 2125

Mains Input Cable (12b)

2125

Burner Air Filter (5)* L102013

Webber Valve (43) (option)

2197

5. Spare Parts.



5.1 Required Spares

 In order to aid troubleshooting and servicing, we

recommend that the components shown thus (*) in this section should be stocked.

Item Description Part No.

Pressure Switch (13)* 202861

Amber Neon (19) (Burner On)

2175

Red Neon (18) (Mains On)

2180

Inline Burner Socket (16)

3123-5

Inline Burner Plug (16b)

3124

Vacuum Test Nipple (43)

L10 4200

Delay Timer (15)* L102026

Main Harness (17): End Vent In-line

E200067 E200068

Lockout Relay (46) (option)

2104

Relay Base (47) (option)

2108

Note: Any spare part components that are not approved by Nortek Global HVAC (UK) Limited could invalidate the approval of the appliance and validity of the warranty.

Only use Smartcom controllers with software version 3.1 or higher.

Refer to g.6b for parts location.

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Item Description Part No.

Burner Gasket (27)* L102032

Ceramic Insert (7) L10 0155

Mica Window (52) A523500

Window Gasket (51) C110 350

B80 Fan B160 Fan B300 Fan

201760 201761 201762

BH300 Fan 201763

100mm (4”) Tube Coupler

C112110

150 mm (6” ) Tube Coupler

C112120

Combustion Chamber

L101020SUB

Combustion Chamber Reector

L105050

Standard Reector

L105024

Item Description Part No.

Burner Head Assy (6)

L100102SUB

Flame Retention (8) L10 0171

Sight Glass Cover (50) A571202

End Vent Module

EVM

Inverters:

1.5kW B80/B160

2.2kW B300

4.0kW BH300 BH300 keypad

900091 900090 N1886

N1886-1*

Contactor O’load

BH300 DOL Only

6129 6131-7

Fan Expansion Joint 7532

Jubilee Clip 7542

Suspension Bracket

C1105 00 SUB

Reector Support Bracket

L201008SUB

Speedlinks 6524

*Must be ordered together

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Gas Typ e Burner

Jet (10) size dia mm / Part No.

Shutter (9) size dia mm / Part no.

EVM Orice Plate dia mm / Part no.

Natural Gas G20

24 4.9 L100549 19.5 L100320 24 L104100

32 5.4 L100 55 4 22 L100314 27 L104093

38 5.8 L100 558 24 L100316 32 L10 4092

46 6.3 L10 0563 26.5 L100318 - -

Propane Gas G31

24 4.0 L10 054 0 19. 5 L100320 24 L104100

32 4.4 L10 054 4 22 L10 0314 27 L10 4093

38 4.8 L100 548 24 L100316 32 L10 4092

46 5.2 L100552 26.5 L100318 - -

5.2 NRV ‘M’ Injector/Air Shutter selection chart

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6. Fault Finding Guide.

Symptoms Possible causes Remedy

Vacuum fan is running but there is no power at burner. Neon lights are o.

Thermostat is satised. Check to see that thermostat is calling for heat.

No power at burner. Check for 240V supply.

Blown fuse in supply to heater. Check and replace if necessary.

End vent vacuum too low.

Vacuum at end vent should be 6.25 mbar (2.5in wg). Check for air leaks on burner.

Air pressure switch on end vent burner not opening. Check and replace if necessary.

3 way air valve (if tted) in end vent burner not opening.

Check and replace if necessary.

No power out from end vent burner. Check for loose or broken wire or faulty relay.

Red neon comes on but ignition sequence does not start and amber neon remains o.

Loose or broken leads to sequence gas controller. Check and repair.

Fault in full sequence gas controller. Replace.

Red neon comes on. Amber neon comes on for ignition period; then amber neon goes o.

No ignition spark.

Check for loose or broken high tension lead to spark electrode.

Check spark gap and position for spark electrode.

Check ceramic is not cracked. Check for loose earth wire connection on

sequence gas controller.

Fault in full sequence gas controller. Replace.

Insucient gas supply to burner.

Check service cock is open and gas pressure is available at inlet to gas valve.

Gas solenoid valve not opening.

Check for loose or broken wires to the gas valve. Check for adequate end vent vacuum. Replace valve if necessary.

Injector pressure not set at zero. Check and adjust.

Incorrect aeration.

Check that air shutter plate on mixing chamber is correctly positioned.

Red neon comes on. Amber neon comes on for ignition period, burner lights for a short time and then goes out. Amber neon o.

Flame probe faulty or lead detached.

Check for broken ceramic. Check for correct position of ame probe.

Fault in sequence gas controller.

Measure ame current. The minimum signal is 3μA (DC).

Polarity of line and neutral incorrect.

Check for correct polarity of the electrical supply.

Burner earth is poor. Check and ensure burner is correctly earthed.

Full sequence gas controller faulty. Replace.

Incorrect aeration.

Check that air shutter plate on mixing chamber is correctly positioned.

End vent vacuum too low (ie below 6.25 mbar (2.5in wg). Check section 3, commissioning for exact vacuum details.

Branch damper closed or broken.

Open branch damper until the correct end vent vacuum is achieved .

Replace damper if necessary.

Fan rotation incorrect. Reverse two phase wires on 3 phase motors.

Fan speed wrong. Check voltage at motor. Replace if necessary.

Fan impeller loose or defective. Tighten or replace if necessary.

Restriction to fan inlet. Clear restriction, repair ue duct.

Air leaks into system via poor joints.

Replace defective tube couplers, gaskets or acoustic joints.

Insucient fall of system towards fan allowing condensate blockage.

Reinstate system fall.

Non return valve sticking open on condensate trap assembly.

Clean valve or replace if damaged.

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7. Replacing Parts.

7.1 Removal of burner assembly.

a: Disconnect electrical supply at burner mains inlet connection.

b: Turn-o gas supply at service cock and disconnect union.

b1 On EVM burners, remove the vacuum tubes by releasing the two compression ttings (14).

c: Release the slider latches (30) from the underside of the burner base plate (1).

d: Pull lid (2) apart and upwards from base (1). Lid is attached to back plate via 2 screws (34).

e: Remove lid by unscrewing set pins (34) from back of base plate.

f: Remove spark electrode assembly (11) (see section 7.6)

g: Release and remove the four set screws (40) from the combustion chamber ange.

Retain combustion chamber gasket (28).

h: Lift burner clear of combustion chamber and withdraw.

i: Remove the burner heat shield.

j: When replacing do so in the reverse order ensuring that the gasket between the burner heat shield and combustion chamber (28) is undamaged or replace if necessary.

k: Check for gas soundness.

7.2 Controller (3) Replacement

a: Disconnect electrical supply.

b: Release the slider latches (30) from the underside of the burner base plate.

c: Pull lid (2) apart and upwards from base (1).

d: Disconnect wiring loom connections from controller (3a).

e: Disconnect ignition wire from controller (3b)

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f: Release three push clips (32) from controller xing holes.

g: Remove controller (3)

h: Replace in reverse order.

7.3 Removal of Gas Valve (4).

a: Remove burner assembly from combustion chamber as detailed in 7.1.

b: Remove controller (3) as described in 7.2

c: Remove Igniter assembly (11) as detailed in 7.6

d: Disconnect earth cable from valve body.

e: Secure burner head (6) and unscrew gas inlet connection.

f: Remove burner casting securing set screws (37)

g: Remove valve bracket set screws (36) from the underside of burner base plate.

h: Withdraw burner head and valve assembly from base plate.

Retain burner gasket (28) for later.

j: Secure burner head (6) and unscrew gas valve (4).

k: Replace in reverse order.

7.4 Filter (5) Replacement.

a: Release the slider latches (30) from the underside of the burner base plate (1).

b: Pull lid (2) apart and upwards from base (1).

c: Unscrew wing nut fastener (33).

d: Slide lter (5) out of location brackets.

e: Replace in reverse order.

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e: Disconnect electrical connections from the timer.

f: Remove xing screws from timer bracket and withdraw.

g: Replace in reverse order.

7.6 Igniter Assembly (11) Replacement.

a: Disconnect electrical supply.

b: Release the slider latches (30) from the underside of the burner base plate.

c: Pull lid (2) apart and upwards from base (1).

d: Remove probe lead (46)

e: Remove xing screws (37) from electrode mounting ange (11).

f: Carefully withdraw electrode assembly from burner - noting electrode orientation.

7.5 Pressure Switch (13) Replacement (EVM ONLY).

a: Disconnect electrical supply.

b: Release the slider latches (30) from the underside of the burner base plate.

c: Pull lid (2) apart and upwards from base (1).

d: Disconnect both silicone tubes (42 & 43) from pressure switch (noting positions).

e: Disconnect three electrical cables from pressure switch (noting positions).

f: Remove xing screws and nuts from the pressure switch bracket and withdraw.

g: Remove retaining screws from bracket to pressure switch and remove unit.

h: Replace in reverse order.

7.6 Delay Timer (15) Replacement.

a: Disconnect electrical supply.

b: Release the slider latches (30) from the underside of the burner base plate.

c: Pull lid (2) apart and upwards from base (1).

d: Remove controller as described in section 7.2

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g: Replace in reverse order.

7.7 Injector (10) Replacement.

(See gure 6a)

a: Turn o gas and disconnect electrical supply.

b: Release the slider latches (30) from the underside of the burner base plate (1).

c: Pull lid (2) apart and upwards from base (1).

d: remove xing screws (37) and air shutter plate (9) from top of burner casting.

e: Remove plug (23).

f: Unscrew brass jet (10) inside mixing chamber using 8mm allen key and withdraw through 1/2in BSP hole.

g: Replace in reverse order.

7.8 Combustion Chamber Viewing Window Replacement.

a: Turn o the system including the vacuum fan.

b: Unscrew dome nuts (53) remove spring washers (54). Remove sight glass cover (50), gasket (51) and mica window (52).

c: Replace in reverse order as shown ensuring components are re-assembled in correct order.

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Notes

Page 56

8.3. Routine Maintenance between Service Intervals

After ensuring that the heater is cold and mains electric isolated, cleaning of the reectors with a soft cloth and a mild detergent (non solvent based cleaners only) in water can be undertaken.

Additional removal of dust from the radiant tubes, burner and heat exchanger can be undertaken.

8.4 Frequency of Servicing

The manufacturer recommends that to ensure continued ecient and safe operation of the appliance, the heater is serviced annually by a competent person e.g. every year in normal working conditions but in exceptional dusty or polluted conditions more frequent servicing may be required.

The manufacturer oers a maintenance service.

Details are available on request.

For Service requirements, please contact Nortek Global HVAC (UK) Limited (details below).

For further technical and service support visit our Support Information Database at www.s-i-d.co.uk

Note This notice must be xed alongside the

electrical service switch.

8.1 To Start the Heater

1. Ensure that gas supply is turned on at each burner.

2. Switch on electrical supply to heaters.

3. Ensure that the following controls are correctly set i.e.;

• Clock.

• Heater program.

• Required room temp.

4. The vacuum fan will operate and at the same time the red neon lights will illuminate at all burners. After 10 seconds the burners closest to the exhaust fan in each radiant branch will light, with both red and amber neons illuminated. After a further 25 seconds the next burner in line within each radiant branch will light and after a further 25 seconds the end vent burner will light.

5 If the lighting up sequence fails and lockout occurs, press the lockout reset button (if available), or switch o the electrical supply and restart after 40 seconds. If lockout occurs three times consecutively switch o and isolate the gas and electricity supplies.

Contact the Nortek Global HVAC (UK) Limited Service department (details below).

8.2. To Switch O Heater

1. Switch o electrical supply to the heater. The burner will stop and the fan will shut o.

2. If the heater is to be switched o for periods in excess of one week it is highly recommended that both the gas and the electrical supplies are turned o.

8. User & Operating Instructions.

Nortek Global HVAC (UK) LTD

Fens Pool Avenue, Brierley Hill

West Midlands, DY5 1QA

United Kingdom

Tel: +44 (0) 1384 489 250

Fax: +44 (0) 1384 489 707

Email: reznorsales@nortek.com

www.reznor.eu/

Registered in England No˚ 1390934 Registered Oﬃce: The Colmore Building, 20 Colmore Circus Queensway, Birmingham, West Midlans, B4 6AT

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Nortek NRV24M, NRV32M, NRV38M, NRV46M Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual