Reznor FSE, FSE 40, FSE 60, FSE 100, FSE 75 Installation & Operating Manual

Floor-Standing
Warm Air Heater

FSE Model Range (Gas & Oil)

Warnings

Nortek Global HVAC 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.

Installation & Operating Manual

Manual Part No.

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

D301160 Issue C

ErP Lot 21

Seasonal Efficiency &
NOx compliant

IMPORTANT NOTICE TO INSTALLERS

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

Additionally it may be necessary to protect

the fuel 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 final
connections then we advise that installers
consult with gas supplier or provider and
satisfy themselves what additional precau

-

tions may be necessary.

Improper installation, adjustment, alter­ation, service, or maintenance can cause
property damage, injury, or death. Read the
installation, operation, and maintenance
instructions thoroughly before installing
or servicing this equipment.

Do not use this appliance if any part has
been immersed in water. Immediately call
a qualified service technician to inspect the
appliance and replace any control that has
been immersed in water.

These appliances are not designed for use
within hazardous atmospheres containing
flammable vapours or combustible dust,
in atmospheres containing chlorinated or
halogenated hydrocarbons or in applications
with airborne silicone substances.

Should overheating occur, or the fuel supply
fail to shut off, close the manual fuel valve
to the appliance before shutting off the elec

-

trical supply.

This appliance is not intended for use by
persons (including children) with reduced
sensory or mental capabilities or lack of
experience and knowledge, unless they
have been given supervision or instruction
concerning use of the appliance by a person

responsible for their safety. Children should
be supervised to ensure that they do not play
with the appliance.

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, specifica­tions, 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 will not be held respon

­sible from any matters arising from the
revision to or introduction of new Laws,
Standards, Directives, Codes of Practice or
other recommendations.

Failure to comply with the information given with these symbols will result in severe personal injury or death and/or property damage.

WARNING CAUTION

WARNING: For your safety, if you smell gas:

• Do not try to light any appliance

• Do not touch any electrical switch, do not
use any phone in your building

• Evacuate all personnel & contact your gas
supplier immediately

• Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of the appliance.

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

• Read the installation, operation and
maintenance instructions thoroughly
before installing or servicing this
equipment.

• Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appliance.

• In case of persisting problems, contact
your distributor

2

CONTENTS PAGE

1. General information 4

1.1 Main safety rules 4

1.1.1 Disposal instructions 4

1.2 Compliance notices 5

1.3 Warranty 5

1.4 Health and safety 6

1.5 Location/Positioning 6

1.6 General requirements 6

1.7 Electrical supply 6

1.8 Design specifications 7

1.9 Identification 7

1.9.1 Receiving the product 7

1.9.2 Fixed protection 7

1.10 Structure 7

1.11 Gas categories and emissions class 10

1.12 Handling 11

2. Installation 11

2.1 Safety area 11

2.2 Air supply and return 12

2.3 Accessories 12

2.3.1 Principle of operation 12

2.4 Fuel connection 12

2.5 Flue gas discharge 12

2.6 Combustion air 13

2.7 Burner assembly 13

2.8 Air intake and supply (ducted units only) 13

2.9 Burner position 14

2.10 Gas Installation/connection 14

2.11 Oil Installation/connection 14

2.12 Fuel supply 14

2.12.1 Storage tank 15

2.13 Pipe work and fittings 15

2.14 Packaging 18

2.15 Flooring 18

2.16 Electrical Installation/connection 18

2.17 Air Distribution Installation 18

3. Burner technical details 19

3.1 Electrical connections 20

3.2 Wiring diagram reference 20

3.3 Control panel 23

3.3.1 Limit safety thermostat 23

3.3.2 Fan thermostat 23

3.3.2.1. TR safety thermostat 23

3.4 Controls 23

3.4.1 Ventilation/Heating 23

3.5 Fan speed control 23

3.6 Starting and stopping 25

3.7 Inspections 25

3.8 Condensation check 25

3.9 Indicators 25

3.10 Fan electric absorption 25

4. Maintenance 26

4.1 Cleaning of gas or oil burner 26

5. Commissioning 27

5.1 Servicing 27

5.2 Start Up Procedure 27

5.3 Stop procedure 27

5.4 Shut down procedure 27

6. Parts list (gas & oil) 28

7. Notes 29

8. Notes 30

9. Notes 31

3

1. General information

This manual is an integral part of the heater,

therefore it should always be carefully kept
and it should always be provided together

with the heater, if it is transferred to another

owner or user. If this manual is damaged
or lost, a new one should be requested
from the installer or from the manufacturer.

After unpacking the product, please check

the contents to ensure all components are
present. If not, please contact your supplier.

The installation must be carried out by

suitably qualified personnel who, at the end
of the work, will commission the appliance
and issue to the owner a copy of the commis­sioning report, which also confirms that the
installation is carried out in accordance

with regulations & standards applicable to

the country of use and in accordance with
the manufacturers instructions.

This appliance has been manufactured

specifically for room heating and must be
used for this purpose. Contractual liability
of the manufacturer in respect of damages
caused to people, animal or premises by
incorrect installation, settings, maintenance
or by improper use of the heater is excluded.
During the initial start-up, there may be the
formation of odours and fumes due to the
evaporation of the oil added to protect the
heat exchanger during storage; this is normal
and will disappear after a short period. It is
recommended to suitably ventilate the room.

If the appliance is to remain unused for long periods,
it is recommended that the following operations
are carried out:

• Turn the appliances' electrical supply off
via the local isolator.

• Close the main fuel supply valve

If there is a long period of time between oper­ation, it is recommended that you contact

your installer to carry out the new start-up.

The heater shall be fitted with approved

accessories only. The manufacturer is not
liable for damages arising from the improper
use of the heater or from the use of non-orig­inal materials or accessories. References to
Laws, Regulations, Directives and Tech­nical Rules mentioned in this manual are
provided only for information purposes
and are in force when the manual is printed.

The entry into force of new provisions

or amendments to current laws does not
represent an obligation of the manufacturer
towards third parties. Repairs or main­tenance are to be performed by trained
personnel only. Do not modify or tamper

with the appliance, the manufacturer will

not be held responsible for any third party
modifications to the heater. The services
that are to be connected (fuel pipes, power

supply, etc.) must be suitably secured and
must not be dangerous with the risk of
tripping.

The manufacturer is responsible for the
product compliance with Laws, Directives
or Construction Rules in force when the
product is marketed. The knowledge and
observance of the laws and standards regard­ing plant design, installation, operation and
maintenance are the sole responsibility of
the designer, installer and user. The manu­facturer shall not be held responsible for
failure to comply with the instructions of
this manual, for the consequences of any
operations carried out and not specifically
provided for or for translations open to
misinterpretation.

The electrical system must feature suita­ble individual and independent electrical
protection for each appliance which, in case
of accidental failure, will be activated on the
single appliance without prejudice to the
proper operation of the other units present
on the installation.

Note: The appliance is designed to be operated with
the heating capacity and the air flow rate specified in
the Data Sheet. If the heating capacity is too low and/or
the air flow rate is too high, combustion products may
condensate, resulting in the irreparable corrosion of the
heat exchanger. If the heating capacity is too high and/
or the air flow rate is too low, overheating of the heat
exchanger may occur, resulting in the activation of the
high temperature safety devices and could cause damage
to the exchanger

1.1 Main safety rules

Please bear in mind that if you use products
powered through electricity, gas, etc., you
should comply with some basic rules, see
below:

WARNING

Children and unassisted disabled people
must not use the warm air heater.

If you can smell gas from or near the heater:

• Air the room by opening doors and
windows;

• Close the fuel control device;

• Promptly request the intervention of a
suitably qualified person.

• Do not touch the unit barefoot or when
parts of the body are wet or damp.

• Do not clean or perform maintenance
before disconnecting the unit from the
electrical power supply after turning the
main electrical supply "OFF", and shutting­off the fuel.

• Do not modify the safety or adjustment
systems without authorization and the
instructions of the manufacturer.

• Do not pull, disconnect and twist the
electrical cables coming from the unit,
even if it is disconnected from the
electrical power supply.

• Do not open the access doors to the inside
of the unit, without turning the electrical
supply to "OFF".

• Do not dispose of, abandon or leave within
the reach of children, the packaging
materials (cardboard, staples, plastic bags,
etc.), as they may be potentially dangerous.

• Do not install the unit near flammable
objects

CAUTION

Nothing should be covering the machine
or be inserted through its case grill and
flue system. Do not touch or stand near
the flue system duct during operation.

• Do not use adaptors, power strips
and extension cables for the electrical
connection of the unit.

• Do not install the unit beyond the limits of
use and operation shown in the instruction
manual.

The warm air heater should not be directly

installed into small areas lacking proper

ventilation, since the air intake might cause

a negative pressure within the space, caus­ing serious problems. It is prohibited to
install the device outdoors and directly
exposed to weathering.

1.1.1 Disposal instructions

Disposing of the appliance must be done by

an authorised company and in compliance
with the applicable laws. Before taking
waste to Authorised Collection Centres,

dismantle and separate the various materials

that compose it which in summary are:

• Ferrous materials

• Aluminium and copper

• Electrical wiring

• Seals and insulating materials

• Plastic materials

• Electronic cards

4

1.2 Compliance notices

The Warm Air Heater range detailed here-

with are 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
modification of then appliance to the condi­tions of use for the country.

The manufacturer has taken reasonable and

practical steps to ensure that all heaters are
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
manufacturer supports all new products
being supplied to their customers with
a comprehensive information pack; this
clearly defines mandatory instructions for
the safe installation, use, and maintenance,
of the appliance(s).

Where proprietary items are incorporated

into any of the Heaters, 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 Warm

Air Heater to ensure that they are familiar

with the appropriate information/manu­als supplied by the manufacturer 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 efficient use.

The manufacturer has a commitment to

continuous improvement and therefore
reserve the right to amend or change the
specification of Warm Air Heater subject to
compliance with the appropriate European,
national and local regulations

1.3 Warranty

The heater is supplied with a 1 year parts

and labour warranty and a further year on
all parts excluding consumables.

The warranty commences from the date

of dispatch from the manufacturer, and
is subject to the terms detailed within the
Manufactures ‘conditions of business’.

Note: The warranty may be invalidated if:

• The installation is not in accordance with
the general requirements of this manual.

• The flue arrangement and air supply for
the heater are not in accordance with the
manufacturers recommendations, codes of
practice, or similar standards.

• Air flow through the heater is not in
accordance with the manufacturers
technical specifications.

• Internal wiring on the heater has been
tampered with or unauthorised service or
repairs undertaken.

• The main electrical supply input to the
heater has been interrupted during the
heating mode.

• The heater has been subject to and affected
by the ingress of water in any form.

• The heater is not operated at the rating(s)
laid down in the manufacturers technical
specifications.

• The heater has not been operated or used
within the normal scope of its intended
application.

• The manufacturer’s recommended
minimum service requirements have not
been complied with.

Note: All warranty claims must contain the following
info to enable processing to take place.

• Heater model

• Heater serial number

• Order reference/date of order, together with
full installation details (name and address)

• Details or symptoms of fault

• Installers name and address

• Commissioning and service records

Faulty parts must be returned to the supplier,
the address of which is provided at the rear
of this manual. Any such parts will undergo
inspection to verify the claim. Replacement
parts supplied prior to this may be charged,
and a credit supplied upon subsequent vali

­dation of the warranty claim. Consumable
items are specifically not included within
the scope of the warranty.

Note: Notification is required the immediate moment a
fault is suspected.

The manufacturer will not accept respon-

sibility for any additional damage that has
been caused, expense incurred, or conse­quential loss resulting from any failure of
the heater(s).

The Warm Air Heater range conforms to the
following standards:

EN 292-1

Safety of Machinery - Basic Concepts, General Prin­ciples for Design Basic Terminology Methodology
EN 292-2

EN 292-2

Safety of Machinery - Basic Concepts, General
Principles for Design Technical Principles and
Specifications

EN 60204-1

Safety of Machinery - Electrical Equipment for
Machines Specification for General Requirements

EN 60335-1

Safety of Household and Similar Electrical Appli­ances General Requirements

EN 50165

Electrical Equipment of non-electric heating appli

­ances for household and similar purposes, safety
requirements

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

EN 1020

Non-domestic forced convection gas-fired air heaters.

Machinery Directive

(2006/42/EC)

Low Voltage Directive

(2014/35/EU)

Electromagnetic Compatibility Directive:
(2014/30/EU)

Regulation (EU)

2016/2281

Gas Appliance Regulations

(EU) 2016/426

Contained within the text of the manual,
the words ‘

Caution

’ and ‘

Warning

’ are used

to highlight certain points.

CAUTION

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

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.

5

1.4 Health and safety

Due account should also be taken of any
obligations arising from Health and Safety
regulations or relevant codes of practice.
In addition the installation must be carried
out in accordance with national or local
regulations and any other relevant Codes of
Practice by a qualified installer. Isolate all
electrical supplies to the heater & controller
before proceeding.

For your own safety we recommend the use
of safety boots and leather faced gloves when
handling sharp or heavy items. The use of
protective eye wear is also recommended.

Before using this appliance:

• Check that the voltage indicated on the
type plate corresponds to the mains supply
voltage.

• Ensure that the heater has been securely
fastened in its final mountain position.

1.5 Location/Positioning

WARNING

The oil variant of the heaters must be
installed in accordance with the current

OFTEC regulations for oil fired products.

WARNING

Under no circumstances should any item

be placed on or above any part of the
heater, whether it is being used or not.

WARNING

All basic criteria must be satisfied prior to
commencing the installation and commis

-

sioning process. The Warm Air Heater must

be positioned and installed to comply with
all relevant standards and guidelines. And
should also meet the local and national fire

regulations and insurance criteria, this is
critical if the heater is to be installed within
a special risk area (e.g. being; within close

proximity to where petrol engined vehicles
are stored or parked, where cellulose spray-

ing takes place, where woodworking

machinery is being operated, etc,).

CAUTION

The heater must not be installed within an
area with unsuitable conditions, e.g. where
the atmosphere is highly corrosive, has a

high degree of salinity, or where high wind

velocities may affect burner operation.

CAUTION

Suitable protection should be provided for
the appliance when it is located in a posi­tion where it may be susceptible to
external mechanical damage; for example,
fork lift trucks, overhead cranes etc.

Indirect heaters must not be located in
hazardous areas, however, it is permissible
for the heater to supply air to such areas.

The heater must not be installed within an

environment where there is a high concen

­tration of chlorides, fluorides, salts, or other
aggressive or volatile chemicals/compounds.
Nor should the heater be positioned where
the burner could be adversely affected by
high winds or draughts.

The location chosen for the heater must allow

for the fitting of an effective flue system.

The location must also allow for adequate

clearance for the air supply, return air circu­lation, gas supply and electrical supply,
whilst also providing good and safe working
access. The heater must be installed on a flat
and level surface made from non-combus­tible material, which is sufficiently robust
to withstand the weight of the heater and
any ancillary equipment.

1.6 General requirements

WARNING

Unauthorised modifications to the appli­ance, or departure from the manufacturers
guidance on intended use on recommended
practices may constitute a hazard. To ignore
the warning and caution notices, and
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 efficient running of the appli­ance itself, and thereby constitute a hazard.

WARNING

All heaters must be earthed.

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
efficient distribution and circulation of
warm air.

• The position of the heater relative to the
route of the flue

• The position of the heater relative to the
supply of fuel

• 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

• The height if applicable at which the
heater is to be mounted and potential
stratification /circulation problems.

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

1.7 Electrical supply

CAUTION

Ensure the fuel supply is in accordance with
the manufacturer’s recommendations and
is as stated on the appliance data plate.

CAUTION

The main electrical supply must not be
switched off or disconnected as a method
for stopping the heater, the exception to
this is in an emergency, or during servicing,
where the heat exchanger has been given
sufficient cooling time to prevent damage
from occurring. Claims for damage will not

be considered if they resulted from incor-

rect wiring or incorrect use of the heater.

Wiring external to the cabinet heater must

be installed in accordance with any local,
national, and European regulations.

The means of connection to the main

electrical supply must allow for complete
electrical isolation of the heater, furthermore,
in the case of a unit wired for a three phase
supply, the supply should only be used to
serve the heater itself and no other plant or
equipment.

The position of the isolation switch must

be such that it is adjacent to the heater and
easily accessible at all times. In addition, the
isolator itself must have a contact separation
of not less than 3mm.

The Control fuse ratings are detailed on the

appliance data plate.

WARNING

Ensure that the electric and gas supplies
are turned off before any electrical work

is carried out on the heater.

Ensure that wiring cannot make contact

with any surfaces liable to be subject to

high temperatures or where the insulation
of the wiring could be impaired as a result
of such contact.

6

1.8 Design specifications

Heat Exchanger

Manufactured from welded stainless steel,
it can be easily inspected for cleaning and
maintenance operations and comprises the
following elements:

• Cylindrical shaped combustion chamber in
stainless steel with low thermal load.

• Heat exchanger elements in steel with
large surface area containing staggered and
opposing indentations.

External casing

The external casing consists of panels in a

pre-painted and/or powder-coated sheet
metal, also includes:

• Frame structure in press-folded profile
with aluminium die-cast corner joints.

• Sandwich panels with internal glass wool
insulation.

Fan assembly

Consists of one or more centrifugal fans

with a low level of sound emission and high

performance.

• Three-phase models are driven by electric
motors with a pulley and belt transmission
system.

• Single-phase models use a direct drive fan.

Safety and control thermostat

The appliances are equipped with ther-

mostats with the sensor located on the air
supply (pre-calibrated and electrically
connected in the factory), with the follow­ing functions:

• “FAN” function (FAN thermostat –
calibration: +25/+35°C). Activates the
fans max. 60 seconds after the burner has
started and stops them approx. 4 minutes
after the burner has switched off.

• “SAFETY” function (TR safety thermostat

- factory calibration + 80°C), has the
function of interrupting the burner
operation in case of abnormal overheating
of the air. It is automatically reset. It shall
be correctly calibrated when it is used for
the first time.

• “LIMIT” function (LM Thermostat - sealed
calibration: +100°C): will stop the burner
if the air becomes overheated abnormally.
Reset is manual.

Flue pipe

The heater is fitted with a circular flue collar

to enable a condense TEE to be inserted
safely and fixed at the start of the flue system.

1.9 Identification

The warm air heaters can be identified through:

• The data plate, applied on the heater, that
specifies the main technical performance
data.

In the event of damage or loss, request a
duplicate from the manufacturer.

1.9.1 Receiving the product

The appliance is supplied with:

• Document envelope including:

• User guide

• Wiring diagram

• Labels with bar code

• Riello burner for installer fitting

• Burner Owner's Manual

1.9.2 Fixed protection

In order to avoid accidental contact with the mova­ble parts of the machine, check if the following fixed
protections have been properly installed:

• Grille on air intake.

• Appliance infill panels.

• Burner casing.

Legend

1. Secondary heat exchangers

2. Combustion chamber

3. Rear flue manifold

4. Front flue manifold

5. Heat exchanger inspection door

6. Flue connection

7. Burner mounting

8. Flame spy hole

9. Fan

10. Fan motor

11. Electrical panel

12. Fan-limit tri-thermostat

13. Smartcom controller

1.10 Structure

Figure 1. Component layout

7

Particular air supply flange:

The upper part of the support frame acts as

a supply flange, which creates a 35 mm stop
on the entire perimeter

Model

A B C Net weight Flue Ø internal

(mm) (mm) (mm) (kg) (mm) (Ønom)

FSE 40

600 770 1500 145 130 5"

FSE 60

650 950 1650 225 150 6"

FSE 75

650 950 1650 245 150 6"

FSE 100

800 1200 1900 310 180 7"

FSE 145

800 1200 1900 345 180 7"

FSE 175

1000 1500 2150 485 205 8"

FSE 225

1000 1500 2150 525 205 8"

FSE 300

1250 1800 2360 660 305 12"

Table 1 – Without burner

Figure 3. Heat exchanger model 40

Figure 4. Dimensions and weight

Figure 2. Heat exchangers models 60–300

8

Model FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Nominal airflow rate m³/h

3500 4800 6300 8300 10900 14000 19000 25000

Technical data (high fire)

Heat input (1) kW

43.0 63.0 75.2 110.0 158.0 195.0 248.0 328.0

Efficiency (NCV) %

90.7 90.1 91.1 90.2 90.8 90.2 90.1 91.5

Gross flue gas temperature (2) °C

210 220 205 215 210 215 220 200

Combustion chamber pressure mbar

0.2 1.1 1.2 1.4 2.0 1.4 1.5 2.9

Heat output (1) kW

39.0 56.8 68.5 99.2 143.5 175.9 223.4 300.0

Fuel consumption (high fire)

G20 natural gas m³/h

4.6 6.7 8.0 11.6 16.7 20.6 26.2 34.7

G25 natural gas m³/h

5.3 7.8 9.3 13.5 19.4 24.0 30.5 40.4

G31 propane gas m³/h

1.8 2.6 3.1 4.5 6.5 8.0 10.1 13.4

G30 butane gas m³/h

1.3 2.0 2.3 3.4 4.9 6.0 7.7 10.2

Heating oil (35 sec) kg/h

3.6 5.3 6.3 9.3 13.3 16.4 20.9 27.7

Nominal temperature rise °C

33 35 33 35 39 37 35 36

Technical data (low fire)

Heat input (1) kW

30.0 41.0 56.7 72.0 106.0 131.2 165.0 244.0

Efficiency (NCV) %

93.5 93.1 93.6 93.2 94.3 94.5 93.1 94.5

Gross flue gas temperature (2) °C

155 155 155 155 140 140 155 140

Combustion chamber pressure Mbar

0.1 0.4 0.5 0.6 0.7 0.5 0.6 1.5

Heat output (1) kW

28.0 38.2 52.9 67.1 99.9 124.0 153.6 230.6

Miscellaneous data

Fan thermostat calibration °C

+35 +35 +35 +35 +35 +35 +35 +35

Limit thermostat calibration °C

+100 +100 +100 +100 +100 +100 +100 +100

Range of use °C

-15/+40 -15/+40 -15/+40 -15/+40 -15/+40 -15/+40 -15/+40 -15/+40

Single-phase power supply V50 Hz

230 1N

Three-phase power supply V50 Hz

- 400 3N 400 3N 400 3N 400 3N 400 3N 400 3N 400 3N

Electric protection IP

20 20 20 20 20 20 20 20

External static pressure Pa

80 150 150 150 150 150 150 150

Supply air fan quantity No.

1 1 1 1 1 2 2 2

Fan size Type

10-10 280 280 355 355 355 355 400

Sound level (3) db(a)

74.0 76.9 81.6 79.8 85.5 76.6 82.7 82.9

Fan motor quantity No.

1 1 1 1 1 2 2 2

Motor power kW

0.4 1.1 1.5 2.2 3.0 1.1 2.2 3.0

Motor max current Amp

4.6 2.5 3.3 4.6 6.2 2.5 4.6 6.2

Motor start up Type

Direct

Table 2 – Technical specifications

(1) Referred to a lower heating power (Hi)
(2) Referred to combustion air temperature +15°C
(3) Sound power at inlet of fan

9

Table 3 – Regulation table

Table 4 – NOx emissions class table (UNI EN 1020 reference):

Model FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Configuration:

B23 B23 B23 B23 B23 B23 B23 B23

Fuel type:

Gas or Oil

Capacity:

P

rated,h

kW

39.0 56.8 68.5 99.2 143.5 175.9 223.4 300.0

P

min

kW

28.0 38.2 52.9 67.1 99.9 124.0 153.6 230.6

Useful efficiency:

n

nom

%

90.7 90.1 91.1 90.2 90.8 90.2 90.1 91.5

n

pl

%

93.5 93.1 93.6 93.2 94.3 94.5 93.1 94.5

Electrical energy consumption:

el max

kW

0.183 0.195 0.197 0.403 0.408 0.430 0.530 0.598

el

min

kW

0.156 0.164 0.170 0.371 0.380 0.375 0.530 0.565

el

sb

kW

0.003 0.003 0.003 0.003 0.002 0.003 0.002 0.003

Other elements:

F

env

%

0 0 0 0 0 0 0 0

P

ign

kW

- - - - - - - -

NOx

mg/

58.6 65.6 69.7 53.6 63.7 59.2 - 96.7

kWh

n

s,flow

%

91.7 91.6 91.4 91.5 90.5 90.8 91.5 90.6

n

s,h

%

72.2 72.3 72.2 72.1 72.2 72.6 72.3 72.7

Legend:

P

rated,h

Nominal heating capacity

P

min

Minimum heating capacity

n

nom

Nominal heating capacity useful efficiency

n

pl

Minimum capacity useful efficiency

el

max

At nominal heating capacity

el

min

At minimum heating capacity

el

sb

In "stand-by" mode

F

env

Envelope loss factor

P

ign

Ignition burner consumption

NOx Nitrogen oxide emissions

n

s,flow

Emission efficiency

n

s,h

Ambient heating seasonal energy efficiency

Country Category Country Category

AL

II2H3B/P, II2H3P

IE

II2H3P

AT

II2H3B/P

IT

II2H3+

BE

I2E(R)B, I3P

LT

II2H3B/P, ll2H3P

BG

II2H3B/P, II2H3P

LU

II2E3B/P

CH

II2H3B/P

LV

I2H

CY

I3B/P, I3P

MC

II2H3B/P, ll2H3P

CZ

II2H3B/P, ll2H3+, ll2H3P

MT

I3B/P, I3P

DE

II2ELL3B/P

NL

II2L3P

DK

II2H3B/P

NO

I3P

EE

II2H3B/P

PL

II2E3PB/P

ES

II2H3+

PT

II2H3+

FI

II2H3B/P

RO

II2H3B/P, II2H3P

FR

II2ER3P

SE

II2H3B/P

GB

II2H3P

YES

II2H3B/P, ll2H3P

GR

II2H3B/P

SK

II2H3B/P, ll2H3+, ll2H3P

HR

II2H3B/P, ll2H3P

TR

II2H3B/P

HU

II2H3B/P

Model FSE

40 60 75 100 145 175 225 300

Class

4

Class 4, for values that are not greater than 100 mg/kWh

Note: Data based on GCV

1.11 Gas categories and emissions class

Always ensure that the gas burner is certified for the

correct category. The unit is certified in EU countries
and countries to soon enter the EU, according to the gas
categories shown below.

Table 5 – Gas categories table – Destination country

10

1.12 Handling

Handling must only be done by a qualified
engineer. If a fork-lift is used, pitchfork the
machine in the lower part using the appro

­priate ways in the wood pallet. Shipping and
handling must be carried out with extreme
care to avoid damage to the unit and danger
to the persons involved.

During transportation and handling, it is
forbidden to stand near the unit. Use the
forklift forks with a minimum length equal
to the width of the machine.

If belts or ropes are used, a rocker arm must
be used (not included) to prevent the pres­sure exerted by the same from damaging the
structure of the unit.

Should it be necessary to place more than
one unit on top of each other, observe the
index indicated on the packaging itself and
be very careful when aligning the packages
so as not to create unstable stacks. If the
device needs to be moved by hand, make
sure that there is enough workforce availa

­ble in proportion with the weight indicated
in Figure 6 “dimensions and weight” and
depending on the distance to cover.

We recommend the use of personal protec

­tive equipment (PPEs).

2. Installation

The installation location must be deter-

mined by the system designer and/or by a
competent person able to take into account
technical requirements, the standards and
regulations in force.

Generally, special permissions need to
be obtained. (e.g.: regulations concerning
zoning, architecture, fires, environmental
pollution, noise emission, etc.).

It is important all users have full permission
before the installation can begin.

To properly install the heater, bear in mind that the
heaters should:

• Be placed on a flat surface, capable of
bearing its weight;

• Be supported over the entire perimeter of
the lower base;

• Be placed on a surface whose deflection
and strength is such that it can prevent
vibrations from reaching underneath;

• Respect the clearance distances in order to
allow for a correct flow of air and normal
cleaning and maintenance operations;

• Maintain the safety distances from
flammable material;

• Be placed close to a flue chimney;

• Be able to be connected to the fuel source

• Be close to an electrical socket;

• Allow for easy maintenance and
inspections;

• Be fitted with the ventilation openings
required by the relevant regulations.

It is forbidden to install it:

• In places where there are aggressive
atmospheres;

• In tight spaces where the sound level of
the heater can be increased by reflections
or echoes;

• In corners where leaves could accumulate
or where other objects could clog the air
passage and reduce the heater efficiency;

• In pressurised places;

• In de-pressurised places;

• Outdoors, if not provided with protection
against bad weather conditions.

Blocks for transportation

To prevent damage during transport, some
mechanical blocks may be installed (red
in colour) that constrain the movement of
certain internal components. The identifi

-

cation and instructions for removal of these

blocks are reported on a self-adhesive label

positioned on the unit.

WARNING

Remove blocks before start-up.

2.1 Safety area

The unit must be easily and safely accessible
without the need for special equipment

(ladders, mobile platforms, etc.). It is impor­tant to keep at least the minimum distance
required to allow normal operation of the
unit and perform maintenance operations

whilst not creating any obstacles to the

flow of air.

Figure 5. Handling

Figure 6. Safety area

11

WARNING

Flue pipes must not go below a height of
2m, and should be guarded against the

possibility of being accidentally touched
by personnel.

Figure 7. Air supply

Figure 8. Flue gas discharge

2.2 Air supply and return

Intake direction and treated air outlet:

• OUT Air supply direction

• IN Air intake direction.

2.3 Accessories

Any accessories must be suitable for instal-

lation, follow the respective instructions
provided.

2.3.1 Principle of operation

The operating principle is described below:

• When the two-stage thermostat detects a
temperature much lower than the set value,
it commands the burner to turn on at the
maximum heat input previously set.

• Approx. 1 minute after the flame has been
ignited, and the ventilation unit starts, it
will release warm air into the room.

• When the thermostat detects that the set
temperature has almost been reached, it
commands switching to low fire.

• When the thermostat detects that the
second pre-set temperature level has also
been reached, it authorises the turn-off of
the burner. After 3–4 minutes, (when the
heat exchanger has completely cooled) the
ventilation unit will also switch off.

• The entire cycle is repeated automatically
according to the instantaneous thermal
requirement of the room to be heated.

2.4 Fuel connection

The heater should be connected to the fuel

supply by a qualified engineer only, comply­ing with the relevant regulations.

As far as gas burners are concerned, we

suggest placing a leak detector near them,
which will operate an electro valve that will
stop the gas supply in case of any accidental
leakage. The gas supply line should be
created by a qualified person, in compliance
with all the relevant Laws, Regulations and
Rules. Refer to the designer of the system.

2.5 Flue gas discharge

Flue gas exhaust connection position and example of connection to the flue:

• Condensate discharge fitting is necessary to
prevent any condensate that has formed in
the flue to flow inside the heat exchanger.

• The vent pipe and the flue connector must
be in compliance with the Regulations and
Laws in force. They must consist of metal
and rigid pipes, capable of resisting the
mechanical, thermal and chemical stress
caused by the combustion.

• It is mandatory that all components of the
flue are certified.

• To avoid reflux of condensation from
the flue to the air heater, there must be a
condensation discharge at the lowest point
of the flue.

• The flue duct cannot rest on the appliance.

• The flue must reach the minimum pressure
required by the current technical standards,
considering “zero” pressure` to the
connection with the flue duct.

• Unsuitable or wrongly sized flues or flue gas
pipes might amplify the burning noise and
negatively effect the combustion parameters.

• Joint seals should be made of materials
resistant to the thermal and chemical stress
caused by the combustion products.

• If walls and/or covers have to be crossed,
this operation should be perfectly carried
out, preventing seepage or risk of fire

• Do not use plastics pipes

We suggest:

• Avoiding long runs of horizontal flue.

• Using metal pipes with a smooth surface
that are capable of resisting the thermal
and chemical stress caused by combustion
products, with the same diameter as the
connector of the heater or larger

• Avoid narrow bends and section reductions;

• Having a trap to take and analyse the
combustion products;

• Anchoring the flue gas discharge pipe;

• Having a proper end cover to prevent
rainwater seepage into the heater and
causing significant friction losses.

• The flue pipe connecting the heater to the
flue should be easily dismantled; to allow
users to easily control and clean inside the
heat exchanger

12

2.6 Combustion air

• The appliance must be installed in
accordance with the regulations in force
and be used only in a well ventilated area.

• The combustion air inlet is always far away
from any obstacles (leaves, sheets of paper,
nylon, etc.)

• Proper air openings should be made in
the building, to comply with relevant
standards for ventilation.

2.7 Burner assembly

The installer is in charge of mounting, elec-

trically connecting and setting the burner.

These operations should be carried out only

by a qualified engineer, carefully comply­ing with the burner and technical manuals
(provided together with the device).

• If the burner does not have a certificate
please contact the manufacturer
immediately, before progressing forward.

• The data for the RIELLO brand burners
are subject to change without notice. We
recommend always consulting the latest
version of the burner instructions.

• The new burner models are in a
continuous stage of improving. For specific
needs, consult the manufacturer.

2.8 Air intake and supply (ducted
units only)

Connect the ducts of the air inlet circuit to
the side opening, the appliance is set up for
both right and left connections.

To change the air inlet side, simply swap the

grille and blanking panels around. To attach
an air inlet duct, remove the grille and attach
the duct to the heater flanges.

The warm air distribution duct is attached to

the flanges at the outlet of the heater. Connec­tion with ducting and/or accessories should
be carried out by fitting sealing gaskets. This
precaution is necessary to ensure the joint is
correctly tightened. In order to prevent vibra­tions from transmitting to the air pipes, we
recommend installing suitable anti-vibration
joints. Check with the plant designer about
installing a fire resistant shutter.

Note: The dimensions of the air inlet and outlet ducts
should be defined by a qualified engineer, on the basis
of the performance specified in Table 2 on page 9.

Figure 9. Air intake and supply (ducted units only)

Intake direction and treated air outlet:

1. Air supply direction

2. Air intake direction

Model

FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Øi

mm

115 145 145 165 165 165 165 200

L

90 90 90 120 120 120 120 125

Table 6 – Burner opening dimensions

Figure 10. Burner opening dimensions

13

2.9 Burner position

The burner must conform to the local stand-

ards and legislations in place.

The RIELLO-burner has been designed to

operate in the position shown in Figure

11, the positions shown in Figure 12, won't

allow the air damper to close when the
burner is on standby.

Figure 11. Correct burner position Figure 12. Incorrect burner position

2.10 Gas Installation/connection

WARNING

The installation must be purged and tested

for soundness prior to commissioning.
Always ensure that appropriate personal

protective equipment is used

Service pipework must terminate at an
approved isolating valve, and be adjacent
to the position of the heater. The connec­tion to the heater can be made by way of
either an approved flexible coupling, or
rigid connection. Threaded connections
must comply with ISO288/1 of ISO 7/1,
further information concerning the accepted
practice in European countries is detailed
in EN 1020.

The diameter of the pipework from the

isolating valve to the burner connection
must not be less than the diameter of the
burner connection inlet.

2.11 Oil Installation/connection

WARNING

Prolonged exposure and contact with gas
oil can result in the natural oils being

removed from the skin, sensitisation can result in
dermatitis.

Always ensure that the appropriate personal

protective equipment is used.

2.12 Fuel supply

WARNING

Galvanised or plastic pipe work and fittings
must not be used. (See BS 5410 Part 1)

The constraints of the application will, to a

large extent, determine whether it is prefer­able to use a single pipe gravity feed system,
or whether the two pipe pumped system is
more appropriate. Where more than one
appliance is to share a common supply it
will be necessary to use a pressurised ring
main system.

All pipe work must be constructed and

installed so that it does not permit the
ingress of air. The construction, size, and
position of the oil storage tank must take
account of the current regulations, as well as
suiting the requirements of the installation.

CAUTION

On pumped systems always check that the
pump is correctly set up prior to operation.
Ensure that valves are open allowing a
free flow of oil through the system.

In order to promote trouble free operating it
is necessary that the oil within the storage
tank and oil line does not fall below the
cold filter plugging point (cfpp), in the UK
and with class D fuel (also referred to as gas
oil). The critical temperature is -4°C for this
summer grade.

The cfpp critical temperature for the winter

grade is -12°C. If summer grade fuel is stored
for winter use in areas prone to severe frosts
and low temperatures it will be necessary
to insulate or even heat the supply tank and
pipe work.

Note: The fuel supplier should be contacted prior to
installation so that any requirements concerning delivery,
transport, storage and use can be addressed before work
commences.

14

The inlet pump pressure must not exceed a

maximum of 0.4 bar, this is because beyond
this point gas is liberated from the oil.

2.12.1 Storage tank

An externally painted steel storage tank to

BS 799 part 5 or a medium density polyeth

-

ylene oil tank OFTEC certified to OFS T-100

may be used. Local, national, European and
fire regulations must also be complied with
and must include:

• A fuel level gauge (not made from glass) a
vent pipe with a diameter greater than that
of the filler and featuring a weatherproof
termination.

• A sludge valve.

• An outlet valve situated at the opposite end
of the tank to the sludge valve.

• A filler pipe connection situated at the
opposite end to the outlet valve.

The size of the storage tank must take

account of the estimated consumption and
any quantity price breaks offered by the oil
supplier. It is preferable to install the tank
outside, however, if this is not practicable
and the tank has to be installed indoors
advice must be sought about its siting, espe­cially so far as fire regulations are concerned.

If a separate fire resistant chamber cannot be
provided for indoor installations, a catch­ment pit with a capacity 10% greater than
that of the storage tank must be provided
storage tanks can if necessary be sited on a
roof, but this is subject to special regulations
as well as local authority approval and
compliance with fire regulations, refer

­ence to BS 5410 part 2 & part 1 is strongly
suggested.

It is advisable to leave the tank unpainted
on the inside, but to paint the outside with
a proprietary grade of anti-corrosive paint.

WARNING

A galvanised or open topped tank is strictly

not allowed. All oil storage tanks require

a bund.

The Control of Pollution Regulation (Oil

Storage) 2001 should be consulted prior to
installation.

Single pipe system (gravity feed)

For installations where the oil tank is

200mm or more above the level of the fuel

pump the principle of gravity feed may be
used. The draw off point for the supply to

the burner must not be positioned any lower
than 100mm above the bottom of the tank.

Where a return valve is fitted this must

be tamper proof to prevent inadvertent
operation.

CAUTION

If the valve is closed when the pump is
running the oil pressure can be increased
sufficiently so as to cause damage to the
seals within the pump.

The return oil should be discharged (pref-

erably) through an elbow onto a tank plate
situated within the tank, this should be
positioned so as not to introduce air or air
bubbles into the draw off pipe.

Two pipe system

This is used where the oil storage tank is

lower than the pump.

Access for the fuel feed to the burner should

be via a suitable tapping made in the top
of the tank, and the fuel feed pipe should
extend to not less than 100mm above the
bottom of the tank. A none return valve
with a metal to metal seat should be fitted,
especially if the return pipe work is termi

­nated at a level above the draw off tube. The
non- return valve must be removable for
service and maintenance purposes, and the
return pipe from the pump must therefore
be extended down into the tank to the same
level as the suction pipe.

The presence of a tamper proof isolating

valve fitted within the return pipe is only
required if there is a risk that oil will siphon
out of the tank if the return pipe is discon­nected at the pump during maintenance or
servicing and if the none return valve has
been omitted.

Pressurised ring main system

This system is used to supply a number of

units from a common storage tank. A booster
pump is used to provide the pressure to
push the oil around the ring main and back
to the tank.

Pressure reducing valves should be fitted on
the delivery pipe to each heater to ensure
that the pressure at the burner pump is less
than 6 psi.

CAUTION

The internal by-pass plug must be removed

from the burner pump when used in a
pressurised ring main application.

2.13 Pipe work and fittings

WARNING

Galvanised or plastic pipe work and fittings

must not be used. (See BS 5410 Part 1)

CAUTION

All joints must be sealed properly, if neces­sary using PTFE tape or other approved
sealing media. The pipe work must be
effectively sealed so as to prevent the
ingress of air. The fire check valve must be
operated by way of a fusible link posi­tioned so that it is above the burner.

Note: It is advisable to check all pipe work prior to

installation to ensure that there is no loose debris or scale
present. The oil feed to each heater must be fitted with
a fire check valve and isolating valve.

Black iron pipes can be hammered to assist
in the removal of these contaminants.

15

H(m)

L metres

8mm I.D 10mm I.D

0.5 10.0 20.0

1.0 20.0 40.0

1.5 40.0 80.0

2.0 60.0 100.0

Figure 13. Typical arrangement of oil storage tank and single pipe system

Figure 14. Pressurised oil feed system

Figure 15. Burner oil pump details 40 - 175 gravity feed from the bottom of the tank

Table 7 – Dimensions

1. Gate valve

2. In-line filter

3. Pump

4. Relief valve

5. Pressure gauge

6. Pressure reducing valve

7. Return to tank

Filler

Maximum 4
metres

Burner

WARNING

Before starting the burner make sure that the
return pipeline is not clogged. Any obstruction
would cause the pump seals to break

Note: All burners are despatched

suitable for gravity feed installations.

16

Table 8 – Dimensions

Figure 16. Burner oil pump details 40 - 175 suction feed

H(m)

L metres

8mm I.D 10mm I.D

0.5 5.0 10.0

1.0 10.0 20.0

1.5 15.0 30.0

2.0 20.0 40.0

H(m)

L metres

8mm I.D 10mm I.D

0.0 35.0 100.0

1.0 30.0 100.0

1.0 25.0 100.0

1.5 20.0 90.0

2.0 15.0 70.0

3.0 8.0 30.0

3.5 6.0 20.0

Figure 17. Burner oil pump details 225-300 gravity feed from bottom of tank

Figure 18. Burner oil pump details 225 - 300 suction feed

Burner

Burner

The pump suction must not exceed 4 metres;
beyond this value the pump becomes noisy.
The return valve must terminate at the same
level as the foot valve, otherwise the pump may
become air locked.

The dimension P should not exceed
4 metres to avoid damage to the

pump seals

The pump suction should not exceed a maximum of 4 metres. Beyond this limit
gas is released from the oil. Oil lines must be completely airtight. The return line
should terminate within the oil tank at the same level as the suction line; in this
case a non return valve is not required.

The return line should terminate within the oil tank at the same level as the suction
line; in this case a non return valve is not required. Should, however, the return line
terminate over the fuel level, a non return valve is essential. This solution, however, is
less safe than the previous one, due to the possibility of leakage in the valve.

Priming the pump: start the burner and await priming. Should lock-out prior to arrival
of the fuel, wait at least 20 seconds before repeating the operation.

17

2.14 Packaging

The heater will usually be supplied wrapped

in heavy gauge polythene, non assembled
parts will be supplied separately.

Prior to installation, the assembly of the
heater should be completed, it is advisable
that this is undertaken in the area where the
heater is scheduled to be sited.

CAUTION

It is strongly advised that when positioning
the heater the lifting eyes are used, thereby
reducing the risk of inadvertent damage

being occasioned to the heater.

2.15 Flooring

The heater must be installed on a level

non-combustible surface capable of support­ing the weight of the heater and any ancillary
equipment.

2.16 Electrical Installation/connection

Cabinet heaters are available either for

415V 50Hz 3PH or 230V 50Hz 1PH supplies

depending upon the model specified.

The electrical supply must be as specified

and suitable for the heater, and must be
run within conduit to a point adjacent to
the heater, and be terminated to provide an
isolation point that will prevent remote or
inadvertent activation.

Cables, conduit, and fittings that are used to
make the connection between the isolator
and the heater must conform to the appro

-

priate local and national regulations.

All heaters are supplied fused and pre-wired,

all must be earthed.

Final connections for any additional exter

­nal controls must be completed on site, and
must be carried out according to local and
national regulations. Separate user infor­mation is provided for the time control unit

and the burner, and forms part of the product
information pack which accompanies every
heater when despatched.

WARNING

Always isolate from the mains electrical
supply before commencing work on the

heater.

Always ensure that the appropriate personal

protective equipment is used.

2.17 Air Distribution Installation

The materials selected must be of low heat

capacity, and it is preferable that all warm
air ductwork is thermally insulated.

Where ducting may be subject to deterio-

ration from exposure to moisture or high
humidity material selection and insulation
are prime considerations. Joints and seams
must be airtight and fastened securely and
designed to remain so, even when operating
at high temperatures.

Adequate support must be designed into

the layout of the ductwork to ensure that
the integrity of the seams and joints is main­tained. The support must be independent
and separate from the heater and the ducting,
to allow for free movement during expan­sion and contraction.

Where ducting passes through walls or

partitions sufficient clearance must be left,
irrespective of any fire stop requirement, to
allow for expansion and contraction. Failure
to adhere to these latter two points can
result in the generation and transmission
of excess noise. Where ducting is installed
in concrete flooring a permanent membrane
must be used to isolate the ducting from
the corrosive effect of the alkaline salts
within the concrete. Care should be taken
to ensure that soft insulation material does
not become compressed and thereby lose
its insulation effectiveness.

The following sub-assembly parts should be

assembled to allow installation to continue.

Vertical Nozzle Models

For free blowing applications it will be
necessary to complete the final assembly
before continuing with the installation.

The nozzles should be pushed home on the

spigots and positioned to provide the desired
airflow. When in the correct position fix in
place with drill screws.

• Ensure louvres are adjusted outwards and
ensure blades are not resonating.

• The nozzles should be securely fixed in

their desired position on completion of

commissioning.

CAUTION

Care should be taken when adjusting the

louvre blades on the outlet nozzles, closing
too many blades could lead to the heater
tripping on high limit. Should this occur
please reset the limit device and gradually
open nozzles until the heater no longer
trips. Please note that fully closing the

louvres on the nozzle above the limit
device should be avoided at all times.

18

Model (Oil)

FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

min max min max min max min max min max min max min max min max

RIELLO burner

mod

RG1RKD RG2KD RG2D RG3D RG3D RG4D RG5D RL32BLU

Nozzle Danfoss 60°S GPH 0.85 1.10 1.35 2.00 3.00 3.50 3.50 1.50 5.50

Pump pressure bar 8.1 12.6 8.0 14.0 8.7 15.0 10.1 13.8 8.0 13.7 8.0 14.4 10.9 10.9 9.7 17.5

Burner head position No. 3.0 9 3.0 5.0 5.0 2.5 6 1.5

Air damper position No. 0.5 3.5 0.5 3 0.7 2.3 0.5 1.1 0.6 3.9 0.7 2.3 0.5 3 2.0 5.5

Measured CO

²

% 12.4 12.54 12.56 12.55 12.64 12.5 12.68 12.24 12.47 12.63 12.69 12.44 12.69 12.52 12.43 12.53

Measured CO

ppm

1 4 1 1 1 1 2 4 1 2 4 2

Measured NO

x

ppm

65 68 68 66 77 85 72 76 62 73 62 69 65 71 47 71

Flue temperature °C 147.5 195.1 202 146.2 163.2 192.9 193 238 168 227 162.2 206.5 118.9 189.5 103.0 192.4

Net flue temperature °C 124.9 172.7 185 128.9 141 171.3 172.2 216.2 144 203.8 137.9 181.8 96.9 168.2 80.3 169.1

Overheat stat temperature °C 50.1 65.9 45 55 52.7 64.8 72 78.1 49 63.1 57.5 69.0 49.2 64.7 49.2 78.4

Ambient temperature °C 22.6 22.4 17 17.3 22.2 21.6 20.8 21.8 24 23.2 24.3 24.7 22 21.3 22.7 23.3

Td °C 10.2 10.1 6.3 6.4 8.7 8.4 11.5 11.7 13.7 13.2 14.3 14.3 9.1 8.9 6.2 6.7

Smoke number No 0 0 1 1 1 0 0 0 0 0

3. Burner technical details

The above data and any pre-calibration at the factory are

non-binding. It is always mandatory to check and adjust the

burner at start-up and in the actual conditions of use.

Model (Gas)

FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

min max min max min max min max min max min max min max min max min max

Riello burner BS1D BS2D BS2D BS3D BS3D BS4D RS34MZ RS44MZ RS35MBLU

Gas pressure mbar 2.9 5.5 2.7 6.1 4.6 7.6 2.6 6.0 4.2 8.6 4.1 9.3 3.7 8.5 5.5 10.0 1.5 5.7

Burner head position No 4.0 1.0 5.0 2.0 5.0 6.5 3.0 2.0 3.0

Air Damper Position

No 1.5 4.0 1.3 2.9 2.2 6.0 0.6 2.0 1.5 5.0 1.5 5.0 40.0 80.0 45.0 70.0 20 43

Measured CO

²

% 9.4 8.9 9.1 9.3 9.5 9.0 9.4 9.2 9.4 9.1 9.3 9.1 9.3 9.2 9.58 9.52

Measured CO ppm 1 14 3 3 2 32 30 23 5 7 18 1 1 1 113

Measured NO

x

ppm 39 32 49 35 39 32 29 37 34 37 32 52 53 54 37 30

Net flue temperature °C 125 185 115 185 130 180 120 195 120 185 120 185 115 185 110 170 105.9 41.4

Table 9 – Two-stage gas burner technical data

Table 10 – Two-stage oil burner technical data

19

Model FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Power supply Single phase 230V¹

Electrical Three phase - 400V¹

Fan motor

Quantity No.

1 1 1 1 1 2 2

2

Unit power kW

0.4 1.1 1.5 2.2 3 1.1 2.2

3

Unit current A

4.6 2.5 3.3 4.6 6.2 2.5 4.6

6.2

Burner

See characteristics of the burner installed

Wiring diagram code FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

8000003938

× - - - - - - -

8000003939

- × × × × × × ×

Table 11 – Electrical data

Table 12 – Wiring diagram code

3.1 Electrical connections

The electric panel is pre-installed with burner,
control and safety thermostat of the FAN-LIMIT
device connected. Please follow the directions
below to get started:

• General power supply;

• Connections to the blown burner;

• Connections to the various external safety
systems (fire dampers, humidifier, fire
protection, etc.).

• Electrical connections must only be carried
out by qualified engineers

• If confused, please contact manufacturer
for further clarification.

• Install upstream of the unit a differential
magneto thermal circuit breaker suitably
sized according to the regulations in force.

• Always connect the earthing system, taking
care to leave the earth wire slightly longer
than the other wires, in the event that the
wires are accidentally pulled, the latter is
the last one to be removed.

• Get a qualified engineer to check that the
section of the cables and the electrical
system are suitable for the maximum
power absorbed by the unit indicated on
the information plate.

• Respect polarity in the connection of the
power supply (phase - neutral). In any case,
make sure that the direction of rotation of
the fans is correct.

• The unit must be connected to an efficient
earthing system. The manufacturer shall
not be held responsible for any damage
caused by failure to earth the appliance.

• The electrical cables must be positioned
away from hot and/or cold surfaces, or
areas with sharp edges.

• In accordance with the Standards regarding
the installation of electrical components, a

device disconnected from the mains with
an opening distance between contacts

that guarantees complete disconnection in

over-voltage conditions III (Standard EN

60335-1) must be included.

• Do not use water pipes or gas pipes to

earth the unit.

• For input and output of the electrical wires,
use the dedicated cable clamps on the unit

The appliance must always be powered. Operation
consent must only be obtained by closing and
opening the contact of the room thermostat.

Power supply voltage ±5%
Frequency 50 Hz
With Neutral

3.2 Wiring diagram reference

The wiring diagram is included as part of

this documentation, and is an integral part
of these instructions. If lost please contact
the manufacturer for a replacement.

We recommend keeping it carefully together with
the other documents.

Should you lose this document, please
contact the manufacturer for another copy,
using the serial number of the appliance.

• If confused, please contact manufacturer for
further clarification.

• Please proceed under the following
standard (Standard EN 60335-1)

• The installation of the general electrical
safety devices (e.g. residual current circuit
breaker) must be executed by the installer
according to the specific applicable
regulations.

20

1. Components key:

2. KM Contactor

3. KM1 Contactor

4. KM2 Contactor (if present)

5. RT Thermal relay

6. RT1 Thermal relay

7. RT2 Thermal relay (if present)

8. M Fan motor

9. M1 Fan motor

10. M2 Fan motor (if present)

11. FAN thermostat

12. LM Manual reset safety
thermostat

13. TR Automatic reset safety
thermostat

14. F1 Fuse

15. BM Single-stage burner terminal
block

16. BP1 Double-stage burner
terminal block

17. BP2 Double-stage burner
terminal block

18. SC Controller terminal block

19. RS Stage switch relay

20. RB Burner relay

Figure 19. Wiring diagram 8000003938

21

1. Components key:

2. KM Contactor

3. KM1 Contactor

4. KM2 Contactor (if present)

5. RT Thermal relay

6. RT1 Thermal relay

7. RT2 Thermal relay (if present)

8. M Fan motor

9. M1 Fan motor

10. M2 Fan motor (if present)

11. FAN thermostat

12. LM Manual reset safety
thermostat

13. TR Automatic reset safety
thermostat

14. F1 Fuse

15. BM Single-stage burner terminal
block

16. BP1 Double-stage burner
terminal block

17. BP2 Double-stage burner
terminal block

18. SC Controller terminal block

19. RS Stage switch relay

20. RB Burner relay

Figure 20. Wiring diagram 8000003939

22

3.3 Control panel

The control panel is located in the lower
left of the front panel, refer to instructions
provided with the control panel.

3.3.1 Limit safety thermostat

The appliance is equipped with a MANUAL
RESET LIMIT safety thermostat with the
element positioned on the air supply. It func­tions to stop the burner if the air becomes
too hot. It can be restored by pushing the
restore button, after removing the causes
that have triggered it.

3.3.2 Fan thermostat

The appliance is equipped with a fan ther­mostat with the element positioned on the
air supply.

Activating the fan max. 60 seconds after the
burner has started and it stops it approx. 4
minutes after it has stopped. Thus, prevent

­ing cold air from being released when the
heater is activated. The thermal energy
accumulated by the heat exchanger will be
disposed of before the fan stops.

3.3.2.1 TR safety thermostat

The appliance is equipped with an auto­matic reset TR safety thermostat with the
element positioned on the air supply. It has
the function of stopping the burner if the air
becomes overheated. Restoring is automatic.

3.4 Controls

For its operation and programming, refer
to the dedicated instructions, which are
supplied together with the appliance.

LIMIT thermostat reset button:

Located on the LIMIT thermostat's interface,
the button will reset the operation of the
burner after it has stopped due to over­heating. Before resetting the device please
verify that the issues have been resolved
before continuing operation. If confused,
please contact manufacturer for further
clarification.

3.4.1 Ventilation/Heating

Operating cycle in fan only mode:

• Power the appliance

• Turn on the unit in fan only mode

At this point, the fan unit will operate and
air at ambient temperature will be released.

Operating cycle in heating mode:

• Power the appliance

• Set the room thermostat to desired
temperature

• Turn on the unit on "heating" mode.

At this point the burner is powered elec­trically, after the pre-purge function of the
combustion chamber, the flame will begin
to ignite. About one minute after the flame
is ignited, the fan unit starts and warm air
will be released.

Once the temperature set on the room ther

­mostat has been reached, the burner stops
and after approx. 4 minutes the fan unit
will also stop.

The entire cycle is repeated automatically
each time the temperature drops below the
value set on the room thermostat.

3.5 Fan speed control

Models 60–300

For all the installations requiring changes
of static pressure, the air flow should be
adjusted to the nominal value accordingly.

The pulley installed on the fan motor(s) is
of the adjustable diameter type.

The heaters ordinarily come with a median
transmission ratio, so a nominal value can
be obtained in installations, as standard.

Begin by checking (when the burner is
operating on the nominal thermal output)
the temperature rise between the air outlet
and inlet temperature and compare with
the specifications of Table 2 on page 9.

Figure 21. Control panel

23

Figure 22. Fan speed control

Figure 23. Fan

Figure 24. Fan belt

In any case, check that the fan rotation
direction matches the direction indicated
by the arrow on the worm-conveyor.

If there is a three-phase electric motor, to
change the direction of rotation simply swap
any two phases of the supply line without
tampering with the wiring of the electrical
panel. It is also necessary to make sure that
the current absorbed by the motor does
not exceed what is indicated on the plate,
adjust—if necessary— the rpm of the fan to
obtain this result.

To adjust the fan speed, proceed as follows:

By increasing the diameter of the drive
pulley, the number of rotations of the fan
and the electric absorption of the motor
increase. The reverse effect will happen if
you decrease the diameter.

Note: In the case of models equipped with more than
one motor, each motor must be adjusted and its electrical
absorption must be checked

To change rpm of the fan, perform the following
operations:

• Relax the belts tension by unloosing the
screw 1

• Remove the belt 4

• Using an allen key, loosen the screws 2 of

the sheave 3 movable part.

• Rotate the sheave of the movable part until

the desired original diameter is reached.

• Firmly tighten the screws 2

• Install the belt 4 and set to correct tension.

Do not excessively stretch the belts as the
fan shaft could break. When you press the
two sides of the belt with your hands it must
be able to bend about 20-30 mm

FSE 40

The fan motor of the FSE 40 appliance

is keyed directly onto the impeller. The
motor is also available in a three-speed
rotation version. It is shipped from the

factory connected at the minimum speed,
which corresponds to the nominal air flow
without residual useful static pressure; if

it is necessary to increase its performance,

simply connect it to the average or maxi-

mum rotation, respecting the wiring diagram

positioned on the fan itself.

24

3.6 Starting and stopping

To Start

The start-up operation must be performed by

qualified engineer, after making sure that the
components of the plant have been installed
properly and that all the safety devices have
been adjusted correctly.

The first start-up consists of the following:

• Close the room thermostat contact: the
burner will start the operating cycle and,
after the pre-purge cycle, the flame will be
ignited

• Check that the fan starts about 1 minute
after the flame is ignited

• Check the combustion parameters

• Wait for the heater to reach full
temperature (20 min.) And make sure that
the limit thermostat does not intervene

• Open the room thermostat contact and
make sure that the burner stops

• Close the room thermostat contact again
and perform a new burner ignition cycle

• Close the fuel shut-off valve and make sure
the burner stops

During the first start-up cycle, the burner
may stop due to the lack of fuel supply. In
this case, wait at least 30 seconds and, after
resetting the burner by pressing the dedi­cated button, repeat the operation.

During the first few hours of operation, it
is common for fumes and odours to form
due to the heating of paints and seals. The
smell will fade by itself within a few hours,
but if it continues for a prolonged period of
time, please contact the manufacturer. It is
recommended to ventilate the room during
this time.

To Stop

To stop the air heater, use the room ther-

mostat only, by setting it to the minimum
temperature or by opening the contact of
the switch itself —if present— or on stop.

Wait for the fan to stop (4 min.) and then,

if necessary, turn the power off from the
main switch.

Never stop the appliance by cutting off the
electrical power, the thermal energy stored
in the heat exchanger may cause danger­ous overheating situations, with possible
damage to the air heater.

Moreover the ‘LIMIT’ thermostat could be
triggered and it might be necessary to release
it manually.

3.7 Inspections

In order to ensure that the heater works
properly, some basic parameters should
be checked.

Turn the unit on and:

• Make sure that the fan unit starts within 60
seconds after the burner is turned on.

With the unit steady (after an approximate 20
minutes of continuous use) perform the following
operations:

• Make sure there are no fuel leaks.

• Check the correct fuel flow rate by weighing
the diesel fuel or reading the gas meter

• Check that the unit's flue gas temperature
and the technical data are similar with a
tolerance of ± 10°C.

• Make sure that the manual resetting safety
thermostat calibration is correct.

• Check that the temperature near the safety
thermostat is correct (ambient temperature

+ air temperature).

• Check that no faults have been reported on
the safety thermostat.

• Check that no faults have been reported on
the safety devices present on the machine.

• Make sure that the temperature gradient is
compliant to the value specified in Table 2
on page 9 with a ±2°k tolerance.

• Re-activate the appliance. Simulate the
intervention of the safety thermostat and
check that the burner turns off. Do not
adjust the factory settings

• Check that the fan electric absorption value
does not exceed the value specified in the
plate.

• Check that the air pressure switch on the
burner is properly calibrated so that it will
turn the burner off in case of an insufficient
flow of combustion air.

• Make sure that the fan operates for another
3/4 minutes after the burner has been
turned off, before it stops.

All of the aforementioned checks must be

carried out. If you want to control the flame
through the flame viewer, you must remove
the threaded plug and make sure that you
wear protective eye-wear.

3.8 Condensation check

The appliance is designed to be operated

with the heating capacity and the air flow
rate specified in the Data Sheet section.

If the heating capacity is too low and/or
the air flow rate is too high, combustion

products may condensate, resulting corro­sion of the heat exchanger.

Check inside of the heat exchanger for
condensation.

This check should be performed by turning

off the burner after half an hour of continu­ous use, checking simultaneously through
the flue connection if there is any trace of
humidity in the flue gas collector and in the
flue gas pipe elements.

There should not be leakage coming from

the safety condensate discharge.

3.9 Indicators

Voltage presence indicator

Placed on the electric panel, it is a green
light indicator, which turns on when there
is a voltage.

Safety devices signaller

Positioned on the electrical panel, consist­ing of a red indicator which lights up when
one of the appliance's safety devices has
intervened.

Burner lock indicator

Located on the burner, is a red light indicator,

which will turn on when the burner is in

lockout.

3.10 Fan electric absorption

To measure the electrical absorption of the appli­ance motor, proceed as follows:

• Insert the current meter on a phase of the
main supply line;

• Set the heater for operation in summer
mode, so as to exclude all other devices
(burner and auxiliaries);

• Read the electric absorption value on the

current meter and compare it with the data
written on the fan plate.

25

4. Maintenance

CAUTION

Maintenance checks should be made more
frequently to appliances close to/or under
particularly hot areas.

• Repairs or maintenance must be performed
by a competent and qualified engineer.

• Disconnect the unit from the main power
and fuel supply before any maintenance
and/or inspection work.

• In order for the heater to properly work
and be maintained, we suggest regularly
cleaning and maintenance checks listed in
the following bullet points.

• Cleaning and maintenance intervals must
be carried out in relation to the appliance
use conditions, to the installation site and
to the environment.

• Any action to this effect must be carried out
safely by a qualified engineer.

• It is recommended that you use personal
protective equipment.

• All maintenance/cleaning operations
requiring the use of ladder or other means,
must be secured safely before use.

• It is advisable to report the changes on/or
to the appliance (date, description, type of
intervention, cause, etc.).

• If you are not going to use the appliance for
long periods of time, turn the main switch

"off". If long periods of unusual operation

occur, it is advisable to contact the
manufacturer on how to restart operation.

• Regularly check that all the screws used to
assemble the heater are properly fixed.

4.1 Cleaning of gas or oil burner

The burner should be cleaned by authorized
personnel, only.

Electro-ventilator cleaning

WARNING

The belts must have enough tension to
prevent sliding on the pulley. Too much
tension on the belts may cause the bear

-

ings and/or shaft to break.

After removing the necessary panels, clean

the component using a wet cloth. Be sure to
periodically check the tension of the trans­mission belts and the alignment between the
motor pulley and the fan pulley. The belts
should not be stretched; if the belt is pressed
on both sides with the hands, it should bend
between 20-30 mm. To manage the tension,
operate the two belt-stretching bolts.

Thermostat safety check

Check functionality of the safety thermostat
at least quarterly. Simulate its intervention
and it should be verified that the burner
goes out.

Checking electrical connections

Periodically check the correct tightening of
all electrical connections.

Security control

Periodically check the operation of all the
safety devices of the unit, by simulating
their intervention and making sure that the
unit stops safely.

Jacket cleaning

With a wet cloth, clean all the inner and outer

surfaces of the jacket. Do not use solvents
and / or abrasives products on the unit.

Flue gas analysis

Combustion control-analysis checks must
be done periodically.

Heat exchanger integrity

Periodically check for cracks and/or leak­ages of the heat exchanger.

The heat exchanger should be cleaned, internally and
externally, by authorized personnel and in compliance
with specific rules. In general, we suggest cleaning
the exchanger at least once a year, at the beginning of
every winter.

For such operation, perform the following operations:

• Disconnect the flue

• Remove the burner (1)

• Remove the panel (2)

• Remove the inspection door (3)

• Remove inspection door with flue connection (4)

• Remove the panel (5)

• Remove the inspection door (6)

• Remove turbulators if present

• With a brush, clean the inside of the fume pipes (7)

• With a vacuum remove any soot that has been deposited in the
front (8) and rear (9) manifolds

• If necessary, use a vacuum, remove any soot that has been
deposited inside the combustion chamber

• If necessary, also remove the side panels and carry out external
cleaning of the heat exchanger

• Reassemble all the pieces, especially considering the tightness and
replacing the gaskets, if needed

• If necessary, also clean the flue pipe

CAUTION

Cleaning of the FSE 40 appliance must be carried out
similarly, considering that the tube bundle(7)
consists of only one row.

Figure 25. Fan belt

26

5. Commissioning

Installation, commissioning and mainte­nance of the warm air heater should only be
performed by qualified technical engineer.

Please contact your supplier for help finding

your nearest service centre.

WARNING

The commissioning engineer must go

through the following with the operator.

• Lighting, shut-down, and operational
information.

• Safety features, data plate, and labelling.

• The requirement for regular inspection ­especially if the heater is within a more
demanding environment - and the need for
regular servicing, carried out by competent
and qualified engineers.

CAUTION

After approximately one hundred hours
of running, the tension on the fan belts
must be checked to ensure that it is correct,
and that the belts have not stretched. It is
strongly advised that this is undertaken

by the commissioning engineer, and not

the operator.

5.1 Servicing

WARNING

Servicing must be carried out on a regular

basis, the maximum interval between

services being one year.

It is a requirement that only suitably quali­fied and competent persons are allowed to
undertake the servicing.

Further details are available from either
the commissioning engineer or from the
manufacturer.

5.2 Start-up procedure

• Enable burner via controller by selecting

‘Heat’ (Relay 2); ‘Heat On’; ‘Heat/Auto’.

(This is dependent on control type
supplied. Refer to individual controller
operating manual).

• Burner will fire and establish within 60
seconds.

• As temperature of heater increases, fan will
operate.

5.3 Stop procedure

• Disable burner by selecting ‘Heat OFF’;
‘Standby’.*

• (*Dependent on control type supplied.
Refer to individual controller operating
manual.)

• The burner will turn off.

• The fan will continue to run until heat
dissipation allows the fan and limit stat to
shut down the fan.

CAUTION

Do not use the main electrical isolator to
turn off the heater, to do so can cause
damage to the heat exchanger and combus­tion chamber and thereby invalidate the
warranty.

5.4 Shut down procedure

Perform the steps in the stop procedure, then
when main fan stops, turn main electrical
isolator off, isolate fuel supply.

Ventilation only

• Enable fan on via controller by selecting

‘Fan only’; ‘Vent only’; ‘Vent/Manual’.*

(*dependent on control type supplied.
Refer to individual controller operating
manual.)

• Fan will operate without the burner for the
set period of the controller.

Lockout situations

If either the burner or the fan and limit stat
go to lockout, the lockout must be cleared
manually before the ignition sequence can
be re-initiated.

CAUTION

Repeated or frequent lockouts must be

investigated and their cause determined
by a qualified and competent engineer.

27

Item/Model FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Burner nat gas
Hi/Lo + Gas train

22-99-579 29-99-571 29-99-571 29-99-572 29-99-572 29-99-585

BS1D BS2D BS2D BS3D BS3D BS4D RS34MZ RS44MZ

Burner gasket

3002698 3005795 3005795 3005813 3005813 3008500

Gas train (including valve & pipe)

3970084 3970084 3970084 3970537 3970537 3970534

MBZRDLE405 MBZRDLE405 MBZRDLE405 MBZRDLE407 MBZRDLE407

MBZRDLE410

Control box

3002967 3002967 3002967 3002967 3002967 3002967

Electrode

3008930

3008931
3008930

3008931
3008930

3008931 3008931 3008932

Probe

3007987 3007988 3007988 3007988 3007988 3007988

Propane conversion kit

30-00-882 30-00-884 30-00-884 30-00-886 30-00-886

30-00-886
30-10-423

Item/Model FSE 40 FSE 60 FSE 75 FSE 100 FSE 145 FSE 175 FSE 225 FSE 300

Burner nat oil
Hi/Lo + Gas train

29-99-602

RG1RKD RG2KD RG2KD RG2D RG3D RG4D RG5D RL32BLU

Burner gasket

3005787

Nozzle 35s

27-00-415 27-00-438 27-00-427 27-00-032 27-00-048 - - 27-01-064

Nozzle 28s

27-00-437

Control box

3001175

Electrode Assy

3007513

Photocell

3007839

Fire valve

28-30-102

Oil filter

29-15-017

Table 13 – Gas parts list

Table 14 – Oil parts list

6. Parts list (gas & oil)

28

Notes

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31

Nortek Global HVAC (UK) LTD

Fens Pool Avenue, Brierley Hill

West Midlands, DY5 1QA

United Kingdom

Tel: [phone]

Fax: [phone]

Email: [e-mail]

Web: www.reznor.eu/

Registered in England No˚ 1390934

Registered Office: The Colmore Building, 20 Colmore Circus Queensway, Birmingham, West Midlands, B4 6AT

AFFIX AGENTS DETAILS HERE

This document replaces the previous, Manual Part No: Reznor, FSE, EN, Oct, 18, D301160 Issue B

Current full Part No.

Reznor, FSE, EN, Dec, 18, D301160 Issue C

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