Instruction Manual for FLEXIHEAT models including: FHG, G Series, G Series Air Heaters, G Series, Air Heaters, Heaters
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Operation and Maintenance Manual - G Series 4 UNITS OF MEASUREMENT The units of measurement used are those of the International System (SI).
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DocumentDocumentINSTRUCTION MANUAL FOR USE AND MAINTENANCE FHG AIR HEATERS Read this manual carefully before installing and operating the appliance INDEX Operation and Maintenance Manual - G Series INDEX ...................................................................................................................................... 2 1 - INTRODUCTION................................................................................................................. 3 1.1 General safety instructions ............................................................................................. 3 1.2 Guidelines for the correct disposal of the product........................................................... 3 1.3 Conventions used in this manual .................................................................................... 3 1.4 Keeping and updating the instruction manual ................................................................. 4 1.5 Target readers ................................................................................................................ 4 1.6 Pictograms...................................................................................................................... 5 1.7 Applications .................................................................................................................... 7 1.8 Versions.......................................................................................................................... 7 1.9 Machine identification data and plates............................................................................ 7 1.10 Description of equipment .............................................................................................. 8 1.11 Transport and handling ................................................................................................. 8 1.12 Warranty ....................................................................................................................... 9 1.13 Manufacturer's identification data ................................................................................. 9 1.14 Declarations.................................................................................................................. 9 1.15 Declaration of conformity ............................................................................................ 10 2 - INSTALLATION................................................................................................................ 11 2.1 Preliminary operations .................................................................................................. 11 2.2 Positioning .................................................................................................................... 11 2.3 Fire prevention guidelines............................................................................................. 12 2.4 Ventilation requirements ............................................................................................... 13 2.5 Electrical connection ..................................................................................................... 13 2.6 Connection to the gas supply line ................................................................................. 13 3 - OPERATION..................................................................................................................... 14 3.1 Preliminary checks........................................................................................................ 14 3.2 First start-up.................................................................................................................. 14 3.3 Start and stop ............................................................................................................... 15 3.4 Using the thermostat socket ......................................................................................... 17 4 - MAINTENANCE................................................................................................................ 18 4.1 General cleaning of the unit .......................................................................................... 18 4.2 Cleaning and replacing the nozzle ................................................................................ 18 4.3 Accessories .................................................................................................................. 18 5 - TECHNICAL SPECIFICATIONS ...................................................................................... 19 5.1 Technical data .............................................................................................................. 19 5.2 Electrical diagrams ..................................................................................................... 20 5.3 Spare parts list ............................................................................................................ 22 6 - TROUBLESHOOTING GUIDE ......................................................................................... 25 2 Operation and Maintenance Manual - FHG Series 1 - INTRODUCTION 1.1 General safety instructions This appliance must only be used for the function for which it was designed: "Gas-fired hot air generator". Any other use is to be considered improper and dangerous. Flexiheat cannot be held responsible for any damage resulting from improper, incorrect and unreasonable use or if the appliance is used in systems that do not comply with the safety regulations in force. Check the integrity of the appliance when you open the packaging, paying particular attention to the presence of damage or deformation which could lead to breakage and/or malfunction during use. In such cases, do not connect the machine to the electricity and gas mains. Periodically carry out a general inspection of the appliance. Comply with the safety rules indicated for electrical equipment, and in particular: · Follow the installation instructions of the appliance. · Do not place any objects on the hot air generator. · Prevent children and/or incapacitated persons from using the appliance without proper supervision; · Do not touch the appliance during operation or during the cooling phase. · Never immerse the appliance in water or any other liquid. · Do not put any objects inside the machine as this could cause irreparable damage. · Do not use accessories, spare parts or components not intended for or supplied by the manufacturer. · Avoid touching the device with wet or damp hands. · Do not pull power cables or expose them to risk of shearing. · Do not leave the appliance directly exposed to the weather (rain, sun, etc.). · In the event of a fault or malfunction, switch it off immediately and disconnect the power and gas supply. · Do not attempt to open or tamper with the appliance: contact a qualified technician. 1.2 Guidelines for the correct disposal of the product Pursuant to European Directive 2012/19/EU: At the end of its useful life, the product must not be disposed of with municipal waste. It can be handed in at the separate waste collection centres set up by the municipalities, or at retailers who provide this service. Disposing of the product separately avoids possible negative consequences for the environment and for health deriving from its improper disposal and allows the recovery of the materials of which it is composed in order to obtain a significant saving of energy and resources. To emphasise the obligation to dispose of electrical and electronic equipment separately, the product is marked with a crossed-out wheeled bin. 1.3 Conventions used in this manual The manual is divided into chapters, within which the operators to whom the instructions are addressed are specified, where necessary, in order to operate the machine safely. The sequence of chapters responds to the temporal logic of the machine's life. To facilitate immediate understanding of the text, terms, abbreviations and pictograms are used, the meaning of which is indicated below. ABBREVIATIONS Cap. = Chapter Par. = Paragraph Page = Page Fig. = Figure Tab. = Table 3 Operation and Maintenance Manual - G Series UNITS OF MEASUREMENT The units of measurement used are those of the International System (SI). 1.4 Keeping and updating the instruction manual The instruction manual must be kept with care and must accompany the machine at all times during its life. Parts must not be removed, torn or arbitrarily modified. The manual should be stored in an environment protected from moisture and heat and in the immediate vicinity of the machine to which it relates. At the request of the user, the manufacturer can supply additional copies of the machine instruction manual. You can request this by writing to sales@flexiheatuk.com The manufacturer reserves the right to modify the design and make improvements to the machine without informing the customer, and without updating the manual already delivered to the user. However, in the event of changes to the machine installed at the customer's premises, agreed with the manufacturer and which involve the modification of one or more chapters of the instruction manual, it will be the manufacturer's responsibility to send the users concerned the chapters affected by the change. It is the responsibility of the user to replace the old chapters, homepage and table of contents with the new ones in all copies owned. 1.5 Target readers This manual is intended for the installer, the operator and qualified personnel authorised to service the machine. OPERATOR: means the person or persons responsible for installing, operating, adjusting, cleaning, repairing and moving machinery and for carrying out the simplest maintenance operations; QUALIFIED PERSONNEL/QUALIFIED WORKERS: these are people who have attended specialised courses, training, etc. and have experience in the installation, commissioning and maintenance, repair, transport of the machine. The machine is intended for industrial use, and therefore professional and not general use, so its use must be entrusted to qualified personnel, in particular who: · have reached the age of majority; · are physically and mentally fit to carry out work of particular technical difficulty; · have been properly instructed in the use and maintenance of the machine; · have been judged by the employer to be suitable for the task; · are able to understand and interpret the operator's manual and safety instructions; · are familiar with emergency procedures and their implementation; · have the ability to operate the specific type of equipment; · are familiar with the specific rules of the case; · have understood the operating procedures defined by the machine manufacturer. The appliance may be used by persons with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, provided that they are supervised or have received instructions concerning the safe use of the appliance and an understanding of the hazards involved. 4 1.6 Pictograms Operation and Maintenance Manual - FHG Series This section explains the meaning of the pictograms indicating the operator's qualification, the state of the machine, the hazards and the obligations/prohibitions to be respected. Their use makes it possible to provide rapid and unambiguous information necessary for the correct and safe use of the machine. PICTOGRAMS RELATING TO OPERATOR QUALIFICATION Symbol Description General labourer: operator without specific skills, able to carry out only simple tasks on the instructions of qualified technicians. Driver of lifting and handling equipment: an operator qualified to use lifting and handling equipment and machines (strictly following the manufacturer's instructions), in accordance with the laws in force in the country of the machine user. Mechanical maintenance technician: qualified technician, able to operate the machine under normal conditions, to make it work with protections disabled, to intervene on the mechanical parts to carry out the necessary adjustments, maintenance and repairs. Typically, he is not qualified to work on live electrical installations. Electrical maintenance technician: qualified technician, able to operate the machine under normal conditions, to make it work with protections disabled, is in charge of all electrical regulation, maintenance and repair work. He is able to work in the presence of voltage inside cabinets and distribution boards. Manufacturer's technician: a qualified technician made available by the manufacturer to carry out operations of a complex nature in particular situations or, in any case, as agreed with the user. The skills are, depending on the case, mechanical and/or electrical and/or electronic and/or software. 5 SAFETY PICTOGRAMS (ISO 7010) Operation and Maintenance Manual - FHG Series Pictograms contained within a triangle indicate DANGER. Pictograms contained within a circle impose a PROHIBITION/OBLIGATION. Pictogram Description Dangerous electrical voltage. General danger. Danger of hot surfaces Do not remove safety devices. It is forbidden to clean, oil, grease, repair or adjust moving parts by hand. Obligation to switch off power before starting work or repairs. Protective gloves are mandatory. Compulsory safety footwear. Helmet use mandatory 6 1.7 Applications Operation and Maintenance Manual - FHG Series The G heaters are direct combustion gas appliances, specifically designed for heating premises in agriculture and livestock applications (poultry farms, greenhouses, etc.). The air is heated using the thermal energy developed by the combustion of the gas and is then sent to the room to be heated together with the products of combustion, thus making 100% of the thermal power produced available. The environment must be suitably ventilated to ensure air renewal and emission control. Do not use the generator in basements or below ground level, nor in rooms used for domestic purposes. The appliance is equipped with all the safety devices required by the standards, which ensure safe operation in all conditions: - Flame control equipment: carries out pre-ignition checks, controls the ignition sequence, checks the presence of the flame during operation and shuts down the machine in the event of anomalies. - Manual reset safety thermostat: protects the appliance from overheating by switching off the burner. - Air pressure switch: intervenes in the event of an abnormal reduction in the air flow rate, causing the flame to extinguish. The materials and components used ensure reliability, corrosion resistance and durability even in the most critical environments. This machine must only be used for the purpose for which it was designed: "Gas-fired air heater for space heating for agricultural and livestock use'. All other uses are improper and potentially dangerous. 1.8 Versions The FG series generators are available in the following versions: 1458200 1458300 1458400 1458500 FHG36-25 FHG45-40 FHG56-65 FHG56-90 25kW 40kW 65kW 90kW 3000m³/h 4000m³/h 7000m³/h 8000m³/h 230V ~ 50Hz 230V ~ 50Hz 230V ~ 50Hz 230V ~ 50Hz 1.9 Machine identification data and plates Each machine is identified by a CE plate on which the machine's reference data are indelibly marked. For any communication with the manufacturer or service centres, always quote these references (Fig. 1.9.1) Fig. 1.9.1 7 1.10 Description of equipment Components of the air heater. Fan motor Thermostat bulb Burner disc Burner Operation and Maintenance Manual - FHG Series Eyebolts for suspension Protection network (inlet side) Fan Protection grid (outlet side) Sensing/ignition electrodes Thermostat reset Burner reset Thermostat socket 1.11 Transport and handling Gas inlet connection ½"M on bottom side Electric box Fig.1.10.1 The machine is properly packed in sturdy cardboard containers. Open the packaging carefully to avoid damage to the machine. Check the integrity of the machine making sure that there are no visibly damaged parts. Do not dispose of packaging elements in the environment: they should be placed in appropriate collection points. The G series generators can be lifted and suspended using the eyebolts provided. ATTENTION! Before moving the appliance: a. stop the machine, b. switch off the power supply, c. interrupt the gas supply, d. wait for the generator to cool down. 8 Operation and Maintenance Manual - FHG Series Use suitable lifting gear to move the machine. The weight is indicated on the nameplate and in the manual at par. 5.1 "Technical data". Carry out the operations with caution, using appropriate personal protective equipment, taking care that the machine does not suffer shocks or fall and positioning the lifting belts correctly. 1.12 Warranty This appliance is guaranteed for 12 months from the date of manufacture for all faults attributable to a proven manufacturing or material defect. The warranty does not cover all parts damaged by transport, bad or incorrect maintenance, neglect, inability to use, improper use, tampering by unauthorised personnel and, in any case, causes not dependent on Flexiheat. During the warranty period, Flexiheat undertakes to provide, free of charge, those parts which are defective at the origin. Repair work must be carried out by a qualified technician authorised. Flexiheat do not cover the cost of labour and offer a parts only warranty 1.13 Manufacturer's identification data 1.14 Declarations The machine is manufactured in accordance with the relevant Community Directives applicable at the time of placing on the market. The machine is not included among those mentioned in All. IV of Directive 2006/42/EC. 9 FLEXIHEAT Company Operation and Maintenance Manual - FHG Series 1.15 Declaration of conformity (Annex IIa Directive 2006/42/EC) THE SUPPLIER UNIT 49-AZURA CLOSE, WOOLSBRIDGE IND. ESTATE THREE LEGGED CROSS, DORSET BH21 6SZ DECLARES under its own responsibility that the machine: Gas fired heater Description 1458200, 1458300, 1458400, 1458500 Article number FHG36-25; FHG45-40; FHG56-65; FHG56-90 Model Gas-fired hot air generator FHG36-25; FHG45-40; FHG56-65; FHG56-90 Trade name Heating of agricultural and livestock premises Intended use complies with the following European Directives: 2006/42/EC EU 2016/426 (2014/35/EU) 2014/30/EU Machinery Directive Gas Appliances Regulation, Cert. n° CE51CS4822 (Low Voltage Directive) Electromagnetic Compatibility Directive Harmonised standards and reference specifications used: EN 12100:2010 EN 525:2009 EN 60335-1:2012 + A11:2014 + A13:2017 EN 60335-2-102:2016 EN 61000-3:2013, EN 55014-1:2017, EN 55014-2:2015 Date of document 20/01/2022 Rev. 00/2022 10 The manufacturer Signature Marco Fantino Administrator Operation and Maintenance Manual - FHG Series 2 - INSTALLATION 2.1 Preliminary operations In order to operate the FHG series heaters, you need: · electrical network with voltage and frequency ratings suitable for the machine, with earth connection and protection devices; · gas supply line with characteristics suitable for the machine Before installing the appliance make sure that: - the local distribution conditions, the type of gas and the supply pressure are compatible with the current setting of the appliance - the local power supply conditions are compatible with the electrical characteristics of the appliance as indicated on the nameplate on the side of the appliance (see section 1.9). 2.2 Positioning FHG series heaters must be installed inside the room to be heated, in a horizontal position, with the electrical box placed to the side and the gas pipe connection pointing downwards. Use the 4 eyebolts supplied as standard to hang or bracket the machine, keeping it in a stable working position by means of a properly sized support structure (see Fig. 2.2.1). The position of the hot air generator inside the room to be heated must be defined by the designer of the system or by a competent person, taking into consideration both technical and legislative aspects (e.g. risk assessment, fire prevention regulations, see par. 2.3 and 2.4). In any case, the following requirements must be complied with: · Any gas cylinders must be used and stored in accordance with the relevant regulations. · Accessibility for maintenance and control operations must always be ensured. · Do not connect any air ducts to the generator's discharge port. · Do not modify the air supply and intake sections. · The device must be used within the ambient temperature and humidity ranges indicated in the technical data table. · Do not install the appliance in rooms with extreme environmental conditions (dust, dirt, etc.) that could impair its proper functioning. · Do not install the unit in environments with a flammable or explosive atmosphere. · Avoid the formation of condensation inside the appliance. Fig. 2.2.1 11 2.3 Fire prevention guidelines Operation and Maintenance Manual - FHG Series Make sure that the installation of the generators complies with all the local and national fire prevention rules and laws in force in the country of destination, if necessary seeking advice from experts or the competent authorities (Fire Brigade, etc.) and, if necessary, obtaining the necessary authorisations. In the absence of more specific regulations or legislation, the following general guidelines should be followed, which are provided for guidance only (Fig. 2.3.1): · The heated room must be completely above ground. · Do not place any combustible materials or objects, or use open flames within 4 m of the hot air generator. · Maintain the following minimum safety distances between the appliance and walls/ceilings: - Minimum distance from ceiling: 1 m - Minimum distance from wall - inlet side: 0.6 m - Minimum distance from side walls: 1 m - Minimum distance from wall - outlet side: 3 m 1 m 3 m 1 m 0,6 m Fig. 2.3.1 12 Operation and Maintenance Manual - FHG Series Provide ventilation openings evenly distributed on the outside walls of the room, with a minimum section as shown in the following table: Model FHG 36-25 FHG 45-40 FHG 56-65 FHG 56-90 Minimum cross-section of ventilation openings per installed FG unit 500 cm2 800 cm2 1300 cm2 1800 cm2 2.4 Ventilation requirements The FG series heaters are direct exchange appliances, which release hot air mixed with the products of combustion into the heated environment. It is therefore necessary, in order to keep the emissions within the safety limits, to ensure an appropriate renewal of the air in the room. According to European guidelines (EN 525:2009, annex C), the system as a whole, including hot air generators, any fans, ventilation openings, etc., must be sized in such a way as to ensure that the air in the room is adequately ventilated. According to European guidelines (EN 525:2009 annex C), the system as a whole, including hot air generators, any fans, ventilation openings, etc., must be sized so that the volume concentration of carbon dioxide (CO2) in the environment does not exceed 0.28% (2800 ppm), particularly in areas where people may be present. The following table shows the theoretical values of the fresh air flow rate to be introduced into the room as a function of the installed heating capacity, in order to maintain a CO concentration <2 0.28% for the most commonly used gases. Minimum fresh air flow rate per kW of installed heat output (m/h3)/kW Fresh air flow rate for each FH G 36-25 installed unit (m/h3) Fresh air flow rate for each FHG 45-40 unit installed (m/h3) Fresh air flow rate for each FHG 56-65 unit installed (m/h3) Fresh air flow rate for each FHG 56-90 unit installed (m/h3) G20 (methane) 37.8 945 1512 2457 3402 G30 (butane) 47.3 1183 1892 3075 4257 G31 (propane) 45.7 1143 1828 2971 4113 2.5 Electrical connection The FHG series heaters are supplied with a power cable and Schuko plug for connection to a single-phase 230V ~ 50Hz mains supply with earth. The heaters are set up for operation with a room thermostat which, when connected to the thermostat socket, automatically controls the start-up and shut-down of the machine according to the set temperature. Alternatively, an On/Off switch can be used for manual control of the appliance (see par. 3.4). · The electrical connection must be carried out by recognised and authorised specialist technicians in accordance with current regulations. · Ensure that the power supply characteristics comply with those indicated on the nameplate and in the manual. · It is mandatory to connect the equipment to an efficient earthing line. In any case, there must be a device for disconnecting the appliance from the mains supply. 2.6 Connection to the gas supply line The FHG series heaters are designed for connection to a gas supply line via a ½" threaded connection on the underside of the electrical box. 13 Operation and Maintenance Manual - FHG Series · Check that the type of gas supplied and the supply pressure are as prescribed on the appliance's nameplate and in the technical data table (see section 2.6). · Connect the appliance to the supply line, providing a manual shut-off valve and, if necessary, a pressure reducer (not supplied). · For connection, only use an approved type of flexible hose with a maximum length of 2m and ensure that it has no constrictions. Do not use rigid hoses. · The gas supply line must be constructed in accordance with the relevant regulations. N.B.: When connecting the gas hose, hold the lock nut on the side of the electrical box with a spanner while tightening the hose fixing nut to avoid excessive torsional stress on the internal fittings, which could compromise the tightness of the same. 3 - OPERATION 3.1 Preliminary checks Before starting up the generator, check that: 1. All connections, both electrical and gas, are made according to the instructions in this manual; 2. The generator is free and clean; 3. The manual gas shut-off valve is open. 3.2 First start-up The operations described in this paragraph must only be carried out by authorised and qualified technical personnel, using suitable personal protective equipment. · Check that the air inlet and outlet sections are not obstructed, even partially; · Ensure that all cables are correctly positioned and that they are not pinched or pulled too tight; · Ensure that the connections to the gas supply line are correct; · Open the tap on the gas supply line (or cylinder); · Check the gas supply line and connection fittings for leaks using leak detector fluid or soapy water; · Check that the supply pressure complies with the specifications in the technical data tables in relation to the type of gas used; · Start up the heater by setting the room thermostat to the desired temperature, or, in the case of manual operation, by energising the appliance via an ON/OFF switch, electrical panel, etc; · Check that the start-up sequence is correct. Start-up sequence Contact on pins 1-2 of the thermostat socket is closed OK Gas valve test (3") OK Pressure switch test: NO contact open? OK Fan start OK Pressure switch test: NO contact closed (4")? OK Estimation (3") OK 14 KO Wait for closure KO Lockout + light signal KO Wait for opening KO Lockout + light signal Flame failure check OK Opening of gas valve and spark OK Flame detection OK Flame on: smooth operation KO Operation and Maintenance Manual - FHG Series Lockout + light signal KO Lockout + light signal Checking and adjustment of working pressures The appliance is equipped with a multifunctional gas valve, which includes two safety solenoid valves and a regulator, and allows you to control the inlet and outlet gas pressures and to regulate the outlet pressure to the burner (see Fig. 3.2.1). The appliance is factory-set for operation in the country of destination, with the type of gas and pressure indicated on the setting data label on the side of the appliance. To check the inlet and outlet pressures, with the appliance in operation, access the gas valve inside the electrical box and carry out the following operations: B - Unscrew the locking screw from the "P IN" socket (ref. A), connect a differential pressure gauge to the socket and check the inlet pressure - Unscrew the locking screw from the "P OUT" socket (ref. B), connect a differential pressure gauge and check the outlet pressure If the pressures are correct (see setting data table), seal the measuring sockets. To adjust the outlet pressure: D - Remove protective threaded cap (C) - Tighten the internal adjusting screw (D) clockwise using a fine-blade screwdriver (5.5x0.8) to increase the outlet pressure and counterclockwise to decrease the outlet pressure. A C - Once adjustments have been made, seal the adjustment screw and reapply the threaded plug (C). Fig. 3.2.1 Model FHG36-25 FHG45-40 FHG56-65 FHG56-90 Type of gas G20 G30/G31 G20 G30/G31 G20 G30/G31 G20 G30/G31 Category II2H3+ II2H3+ II2H3+ II2H3+ II2H3+ II2H3+ II2H3+ II2H3+ Nozzle 4.30 mm 2.40 mm 5.50 mm 3.00 mm - 4.20 mm - 4.70 mm Inlet pressure 20 mbar 28/30-37 mbar 20 mbar 28/30-37 mbar 20 mbar 28/30-37 mbar 20 mbar 28/30-37 Output pressure 9.0 mbar no adjustment 9.0 mbar no adjustment no adjustment no adjustment no adjustment no adjustment 3.3 Start and stop Start To start the heater, set the room thermostat to the desired temperature, or set the external switch, which may be provided in the electrical system in case of manual operation, to ON. 15 Operation and Maintenance Manual - FHG Series During operation · In the event of an abnormal reduction in the air flow rate, the pressure switch trips, the machine locks out and the lock indicator light comes on. · In the event of flame failure or combustion anomalies, the machine makes three attempts to reignite. If the flame does not re-ignite, the machine stops and the lockout warning light illuminates. · In the event of abnormal overheating of the machine, the safety thermostat trips, the machine makes three attempts to restart and then locks up. · When the desired temperature is reached in the room, the contact on the thermostat socket opens and the heater stops without signalling. The appliance restarts automatically by performing the start-up sequence when the temperature falls and the contact closes again. If the appliance breaks down · Look for and eliminate the cause of the blockage (flame failure, reduced air flow, gas shortage, overheating, etc.). If necessary, contact qualified personnel. · Press and hold the Reset button for at least 3 seconds. The signal lamp goes off and the B start-up sequence is repeated. If the appliance still freezes, switch it off and contact the service department (Fig. 3.3.1, A). If the safety thermostat trips · Switch off the power, turn off the gas and wait for the appliance to cool down completely. · Look for and eliminate the cause of A overheating. If necessary, contact qualified personnel. Fig. 3.3.1 · Unscrew the protective cap of the thermostat reset button on the side of the electrical box, press the thermostat reset button and then the luminous Reset button to restart. If the appliance does not restart, or if the safety thermostat continues to trip, contact the service department (Fig. 3.3.1, B). ATTENTION! The unit releases a high temperature air flow. Do not place any flammable objects or materials within 4m of the generator's air outlet. During normal operation, and for some time after shutdown, some parts of the machine can reach very high temperatures! Always use suitable personal protective equipment. Stop · In the case of operation with a thermostat, the heater stops automatically when the desired temperature is reached. In manual operation, cut the power off by turning the switch, if fitted, to the OFF position. Seasonal use The FHG series heaters are mainly intended for seasonal use. At the end of the winter season, or in general if the appliance is not used for long periods: - Disconnect the appliance from the power supply and close the gas supply valve. - Carry out a thorough general cleaning of both the external surfaces and the internal parts (fan, burner, etc., see also sections 4.1 and 4.2). - At the beginning of the next winter season, before using the appliance again, restore the power and gas supply and carry out a complete check-up of the machine. 16 3.4 Using the thermostat socket Operation and Maintenance Manual - FHG Series The FHG series heaters are equipped with a room thermostat socket for automatic or manual control of the appliance. The thermostatic socket is supplied with a protective cover with an internal jumper between terminals 1 and 2 which, when inserted into the socket, enables the machine to be switched on as soon as it is powered. Remote on/off can also be controlled by means of a room Ventilation thermostat, timer, control unit, or manually by means of a (G56-90) switch, etc., always closing a contact between terminals 1 and 2 of the supplied plug. Remote on/off can also be controlled via a room thermostat, timer, control unit, or manually via a switch, etc., always by closing a contact between terminals 1 and 2 of the supplied plug. On the G56-90 model, you can enable the ventilation-only function by closing a contact between terminals 1 and 3 (Fig. 3.4.1). Common Heating Fig. 3.4.1 Fig. 3.4.1 17 Operation and Maintenance Manual - FHG Series 4 - MAINTENANCE The operations described in this chapter must only be carried out by authorised and qualified personnel, using suitable personal protective equipment. Before carrying out any work: switch off the power, close the gas valve and ensure that the machine has cooled down completely. 4.1 General cleaning of the unit Clean the external surfaces regularly, with appropriate frequency depending on the conditions of use, and in particular the air intake and outlet grilles, which must always be perfectly free of any obstructions. Regularly clean the machine body, fan, surfaces and internal components with a soft, damp cloth and a non-toxic, solvent-free cleaning agent, wiping carefully and if necessary using compressed air to remove deposits of dust and dirt. Do not direct water jets, even indirectly, at the motor, burner or electrical parts. Check the tightness of screws and bolts periodically, especially in the event of unusual noises and vibrations. 4.2 Cleaning and replacing the nozzle Use a size 7 hex spanner to remove the four screws securing the protective grille on the suction side of the generator. Unscrew the nozzle from the nozzle holder using a size 13 hex spanner (Fig. 4.2.1). Check and clean the nozzle using compressed air and make sure that the internal hole is perfectly free of impurities. If necessary, replace the nozzle with one of the same diameter. Refit the nozzle, close the door and check operation. If a change of gas is required (e.g. from methane to propane/butane), replace the nozzle and adjust the outlet pressure of the gas valve with reference to the setting data table (see Section 3.2). Venturi Nozzle tube Fig. 4.2.1 Nozzle holder 4.3 Accessories A full range of accessories is available to match your heater, such as electronic thermostats, brackets, air outlet deflectors. Ask your supplier for the accessories catalogue for more details. 18 Operation and Maintenance Manual - FHG Series 5 - TECHNICAL SPECIFICATIONS 5.1 Technical data HEATING POWER AIR FLOW GAS CONSUMPTION @ 1013 mbar/15°C POWER SUPPLY ELECTRICAL POWER NOISE at 1 m OPERATING CONDITIONS DIMENSIONS WEIGHT PACKAGE DIMENSIONS * @30°C without condensation G30 G31 G20 Voltage Current Temperature Relative humidity* A B C L B C kW kcal/h m³/h cfm kg/h kg/h m³/h V/Hz A W dB(A) °C % mm kg mm FHG36-25 25 21500 3000 1765 1,82 1,79 2,38 230~50 1,5 265 73 360 800 520 20 800 600 400 FHG45-40 40 34400 4000 2355 2,91 2,86 3,81 FHG56-65 65 55900 7000 4120 5,09 5,00 5,91 230~50 230~50 2,0 2,7 285 475 71 71 -15/+35 95 450 560 800 930 630 750 22 32 800 1200 600 800 400 650 FHG56-90 90 77400 8000 4710 6,55 6,43 8,58 230~50 4,0 800 71 560 930 750 32 1200 800 650 19 5.2 Electrical diagrams Operation and Maintenance Manual - FHG Series The power cables used must be of a cross-section and type suitable for the electrical ratings of the equipment. Install a differential magnetic circuit breaker in the electrical system upstream of the appliance. (see par. 5.1 - Technical data). Ensure that all electrical connections on the terminal block and components are secure, that the box cover is tightly closed and that the closing screws are tightly tightened to ensure the required degree of protection and insulation. MODELS FHG 36-25, FHG 45-40 Reset button Safety thermostat Air pressure switch Warning lamp Fuse 20 MODELS FHG 56-56, FHG 56-90 Operation and Maintenance Manual - FHG Series 1-2 HEATING 1-3 VENTILATION Reset button Safety thermostat Air pressure switch Warning lamp Fuse 21 5.3 Spare parts list Operation and Maintenance Manual - FHG Series Use only original spare parts. Orders must be placed specifying the following: - Model - Part number - Quantity - Shipping address Pos. 1 1.1 2 2.1 3 3.1 4 4 5 6 7 7.1 8 8.1 9 9.1 10 10.1 11 FHG36-25 1201006 1203004 1451500 1203005 7302003 1257500 8101510 8101643 1404000 1451001 - 1203008 1451004 1203006 5002001 1203007 5102011 1203009 6002010 FHG45-40 1301006 1203004 1452500 1203005 7302003 1257500 8101515 8101551 1404000 1452001 - 1303008 1452003 1203006 5002001 1203007 5102012 1203009 6002010 Qty Description 1 Protection network 1 Protective net fixing kit 1 Complete burner 1 Burner fixing kit 1 Spark plug block 1 Ignition/detector spark plug block fixing kit 1 Nozzle G30/G31 (Propane/Butane) 1 Nozzle G20 (Methane) 1 Nozzle holder with ring nut 1 Generator body 1 Complete electrical box 1 Electrical box fixing kit 1 Motor bracket 1 Motor bracket fixing kit 1 Fan motor 1 Motor fastening kit 1 Fan 1 Fan mounting kit 4 Eyebolt 22 Operation and Maintenance Manual - FHG Series Pos. 1 1.1 2 2.1 3 3.1 4 5 6 7 7.1 8 8.1 9 10 10.1 11 11.1 12 FHG56-65 1401006 1203004 1453500 1403005 7302003 1257500 8101525 - 1404000 1453001 - 1403008 1453004 1203006 1453003 5202002 1403007 5102013 1403009 6002010 FHG56-90 1401006 1203004 1453500 1403005 7302003 1257500 8101559 - 1404000 1453001 - 1403008 1453004 1203006 1453003 5202003 1403007 5102014 1403009 6002010 Qty Description 1 Protection network 1 Protective net fixing kit 1 Complete burner 1 Burner fixing kit 1 Electrode block 1 Ignition/detector electrode block fixing kit 1 Nozzle G30/G31 (Propane/Butane) 1 Nozzle G20 (Methane) 1 Nozzle holder with ring nut 1 Heater body 1 Complete electrical box 1 Electrical box fixing kit 2 Motor support side bracket 1 Motor bracket fixing kit 1 Motor bracket 1 Fan motor 1 Motor fastening kit 1 Fan 1 Fan mounting kit 4 Eyebolt 23 Operation and Maintenance Manual - FHG Series ELECTRICAL BOX Pos. 1 2 2.1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17.1 18 19 19.1 19.2 19.3 G36-25 1451005 7303000 1451002 7301005 7307005 7307006 7305503 1453502 7004000 5005011 8101005 1201022 7302100 8100104 1454302 1454100 8102001 7303007 1451520 1454005 1451006 24 FHG45-40 1452005 7303000 1453002 7301005 7307005 7307006 7305503 1453502 7004000 5005011 8101005 1201022 7302100 8100104 1454302 1454100 8102001 7303007 1452020 1454005 1451006 FHG56-65 1453005 7303000 1453002 7301005 7307005 7307006 7305503 1453502 7004000 5005012 8101005 1201022 7302100 8100104 1454302 1454100 8102000 7303007 1453020 1454005 1451006 FHG56-90 1453005 7303000 1453002 7301005 7307005 7307006 7305503 1453502 7004000 1454215 5005013 7301100 7304001 8101005 1201022 7302100 8100105 1454312 1454110 8102000 7303007 1453020 1454005 1451006 Qty Description 2 Box support 1 Safety thermostat 1 Thermostat bulb bracket 1 Light Reset button 1 Room thermostat socket 1 Room thermostat plug 1 Thermostat socket cap 1 Electric box w/cover 1 Power cable with plug 1 Motor relay 1 Capacitor 1 Fuse holder 1 Fuse 5x20 4A 1 Straight fitting 1 Gas connection washer 1 Flame control board 1 Gas valve complete with fittings 1 Complete terminal box 1 Wiring kit 1 Flexible gas hose 1 Safety pressure switch 1 Air hose pressure switch 1 Pipe fixing bracket 1 Pressure switch bracket Operation and Maintenance Manual - FHG Series 6 - TROUBLESHOOTING GUIDE The operations described in this chapter must only be carried out by authorised and qualified personnel, using suitable personal protective equipment. Before carrying out any work, disconnect the appliance from the mains supply and close the gas interception valve. Defect Cause Power failure Room thermostat not connected or set to too low a temperature Thermostat socket cap not inserted (in manual operation) Faulty room thermostat Blown motor protection fuse Motor/fan blocked or defective The fan does not start Previous triggering of an external thermal motor protection (if fitted) Pressure switch contact open or blocked (does not close/do not open) Previous triggering of the safety thermostat The appliance is in lockout mode (indicator lamp lit) Faulty flame control device or blown internal fuse Solution Check the electrical connections and the power supply network (electrical panel, circuit breaker, fuses, external switch, etc.). Connect room thermostat and/or set it to higher temperature Insert thermostat socket cover Check and replace the thermostat Check and replace Check that the motor and fan can rotate freely. Check voltage at motor terminals. Replace if necessary Check that the motor rotates freely, inspect the air passage sections, check the thermal protection setting Check pressure switch, clean contacts, replace if necessary Search for and eliminate the causes of overheating (e.g. reduction of air inlet/outlet sections, etc.), and reset the safety thermostat and press the release button Search for and eliminate the causes of the blockage and press the reset button Check the equipment and the internal protection fuse. Replace if necessary 25 Operation and Maintenance Manual - G Series The fan starts, but the flame does not ignite and the appliance goes into lockout. Generator not heating enough or heating too much Generator goes into lockout (or stops) during operation No gas from the supply line Check gas supply line, open manual valve if necessary Solenoid valves do not open Check that voltage is reaching the solenoid valves, replace if defective Incorrect supply pressure or burner pressure Check adjustments and correct if necessary Incorrect gas type Check that the type of gas used is one of those indicated on the plate No ignition spark Check and clean the ignition electrode, check the electrical connections and the flame control equipment. No or weak flame signal (even in the presence of a flame) Check and clean the flame sensor, check the electrical connections and the flame control equipment. Faulty flame control equipment Check and replace equipment Incorrect supply pressure or burner pressure Check adjustments, correct if necessary Incorrect gas type Check the type of gas used, replace if necessary Partial obstruction of air inlet/outlet sections Check and maintain clean and clear air inlet and outlet sections Insufficient or excessive installed power Review the sizing of the system for the room to be heated Lack of voltage Check the electrical installation (cables, distribution board, circuit breaker, fuses, etc.) and restore power Gas shortage Check the gas supply line Flame failure and/or combustion anomalies (no or weak flame signal) Check that the operating pressures and gas used are correct, check the nozzle and clean it if necessary Check flame sensor, connection cable and flame control equipment, replace if necessary Air flow reduction (pressure switch tripping) Check that the air inlet and outlet ducts are completely clear, remove any obstructions Check that the motor and fan rotate freely (at the correct speed) Replace defective parts if necessary Appliance overheating (safety thermostat tripping) Check that the operating pressures and type of gas used are correct Check that the air inlet and outlet ducts are free of obstructions and that the motor/fan rotates freely Faulty flame control device, safety Check function of components, clean contacts, thermostat or pressure switch (action in check connections, replace if defective the absence of problems) 26 Operation and Maintenance Manual - FHG Series 27 Operation and Maintenance Manual - FHG Series 28Microsoft Word per Microsoft 365 iLovePDF