Winterwarm XR Manuale utente

XR - en - v2.0 - 12 / 2019

INSTALLATION MANUAL

AIR HEATER

TYPE XR

Content

1 Introduction 3

1.1 Symbols used in this manual 3

1.2 Warranty 3

2 Safety instructions 3

2.1 Installation 3

2.2 Use 4

2.3 Maintenance & Cleaning 4

2.4 Children and vulnerable users 4

3 Technical speciﬁcations 4

3.1 Performance 4

3.2 Gas types 5

3.3 Dimensions 6

4 Installation 7

4.1 Preparation 7

4.2 Positioning the air heater 7

4.3 Gas type & connection 9

4.4 Electrical connection 9

4.5 Room thermostat 9

5 Flue systems 12

5.1 Flue terminals 12

5.2 Flue length (max.) 13

5.3 Condensate in the ﬂue system 13

5.4 Installation of the ﬂue terminal 14

6 Operating the air heater 16

6.1 Burner cycle 16

6.2 Minimum ﬁring time 16

6.3 Delta-T-regulation 16

6.4 Summer ventilation 17

6.5 Overheating protection 17

6.6 Flue passage check 17

7 Commissioning the air heater 17

7.1 Adjusting the settings 17

7.2 Commissioning the air heater 17

8 Combustion settings 18

8.1 Adjusting the burner settings 18

8.2 Converting to another gas type 19

9 Troubleshooting 19

9.1 Volatile lock outs 19

9.2 Temporary errors 20

9.3 Warnings 20

9.4 Instructions 20

9.5 Further troubleshooting 21

10 Maintenance 22

10.1 Preparation 22

10.2 Basic maintenance 22

10.3 Maintenance of the burner unit 22

11 Electrical wiring diagram 24

12 Exploded view and spare parts 25

13 Declaration of conformity 26

INSTRUCTION MANUAL AIR HEATER TYPE XR

1 Introduction

This manual is intended for the gas, electrical and

mechanical installer.

This document gives instructions on how to use and

maintain the air heater. It is most important to follow the

instructions in this document for safe operation of this air

heater.

It is important to read this document before starting the

installation process. Store this document close to the air

heater for quick reference.

1.1 Symbols used in this manual

DANGER! Indicates a dangerous situation that would lead

to death or severe injury.

WARNING! Indicates a potentially dangerous situation

that could lead to death, severe injury or serious product

damage.

CAUTION! Indicates a potentially dangerous situation

that could lead to injury or product damage.

NOTICE Indicates important information that is not

directly related to safety.

1.2 Warranty

NOTICE Using, installing or maintaining this air heater in

any other way than described in this manual may cause

damage that voids the warranty.

NOTICE Failing to follow the safety instructions in this

manual can lead to damage to the air heater or the

installation and void the warranty.

2 Safety instructions

Always follow the safety instructions in this chapter when

installing, using or performing maintenance on this air

heater:

2.1 Installation

CAUTION! This air heater must be installed and

maintained by an authorized, qualiﬁed and competent

installer, using calibrated equipment.

NOTICE This air heater must be installed and maintained

in accordance with this manual, national and local building

regulations and local health and safety regulations.

2.1.1 Protection against dust

CAUTION! Do not use the air heater in a very dusty

environment. Dust may accumulate and cause a defect of

the heater. This is also the case for the room thermostat.

2.1.2 Temperature

CAUTION! Do not install the heater in places where the

temperature can rise above 35°C. Higher temperatures

cause the internal components to degrade much faster.

NOTICE Air heaters installed in very cold environments

may form condensate in the ﬂue system. Make sure a

condensate discharge is installed.

2.1.3 Corrosive vapours

WARNING! Do not install the air heater in areas that

contain any corrosive or explosive vapours. Corrosive

vapours (e.g. containing Chlorine) that are sucked into the

air intake will cause corrosion of the heat exchanger and a

leakage of condensate and ﬂue gas. This is also the case

for the room thermostat.

2.2 Use

CAUTION! Make sure the area around the air heater is

dry when performing maintenance on the air heater.

CAUTION! Always close the doors and inspection hatches

of the air heater, except when adjusting and checking the

appliance.

2.3 Maintenance & Cleaning

Frequent maintenance and cleaning of the air heater is

necessary to ensure safe and proper operation. Failure

to do so could lead to damage to the heater or its

surroundings and void the warranty.

2.3.1 Protection from water (IP class)

WARNING! Never use water when cleaning electrical

parts.

This air heater is not waterproof and has an IP00B

classiﬁcation.

WARNING! Do not expose the air heater to rain, spray or

dripping water.

2.4 Children and vulnerable users

WARNING! This air heater can be used by children aged

8 years and above and by persons with reduced physical,

sensory or mental capabilities or lack of experience and

knowledge, if they are supervised or instructed concerning

use of the appliance in a safe way and understand the

hazards involved.

WARNING! Children shall not play with the air heater.

WARNING! Children shall not clean and maintain this air

heater without supervision.

3 Technical speciﬁcations

3.1 Performance

Technical speciﬁcation Unit Type XR-4.1 (ERP2018)

XR10 XR20 XR30 XR40 XR50 XR60

Net nominal heat input (max.) kW 14.0 22.8 32.0 44.0 55.0 66.0

Net nominal heat input (min.) kW 9.0 14.8 20.5 26.4 33.0 39.6

Heat output (max.) kW 12.8 20.8 29.2 40.2 49.9 60.5

Heat output (min.) kW 8.3 13.8 19.1 24.4 30.8 37.0

Eciency at max. power % 91.4 91.3 91.1 91.4 90.7 91.7

Eciency at min. power % 91.7 93.0 93.1 92.4 93.3 93.4

Air output (max.) m3/h 1150 2070 2600 4370 5150 6300

Throw horizontal (max.) m 12 16 23 26 28 30

Throw vertical (max. warm) m 5 5 6 7 7 8

Gas connection G” 1/2" 1/2" 1/2" 3/4" 3/4" 3/4"

Electrical connection (50 Hz) V 230 230 230 230 230 230

Electrical power consumption

(max.)

kW 0.250 0.250 0.250 0.450 0.450 0.600

Electrical power consumption

(min.)

kW 0.250 0.250 0.250 0.450 0.450 0.600

Stand-by electrical power

consumption

kW 0.004 0.004 0.004 0.004 0.004 0.004

Electrical current A 1.1 1.1 1.1 2.0 2.0 2.6

Protection class - IP00B

INSTRUCTION MANUAL AIR HEATER TYPE XR

Technical speciﬁcation Unit Type XR-4.1 (ERP2018)

XR10 XR20 XR30 XR40 XR50 XR60

Emission eciency (ηs, ﬂow) % 96.1 93.3 90.6 91.7 91.2 90.8

Seasonal space heating

eciency

% 76.3 74.8 72.8 73.8 74.1 73.7

NOx emission (GCV) mg/kWh 37 36 35 43 41 42

NOx class - 5 5 5 5 5 5

Flue gas amount (max.) kg/h 21.7 35.5 51.3 70.6 88.2 105.8

Thermostat communication bus

system (low voltage)

- 2-wire low voltage communication bus

Chimney ﬂue pressure (max.) Pa 90 90 90 120 120 120

Sound level (at 8 m) dBA 42 45 45 46 47 49

Min. suspension height

(horizontal throw)

m 1.7 1.7 1.7 1.7 1.7 1.7

Flue length m 9 9 9 9 9 9

Weight kg 36 37 38 78 80 82

3.2 Gas types 3.2.1 Natural gas G20

Speciﬁcation Unit Natural gas G20

Nominal supply pressure mbar 20

Supply pressure (min. - max.) mbar 17-25

Gas category - I2H

BE: I2E(s)

FR: I2ESI

NL: I2EK

DE: I2ELL

Class - B23, C13, C33

Speciﬁcation Unit XR10 XR20 XR30 XR40 XR50 XR60

Gas consumption (max.) m3/h 1.5 2.4 3.4 4.7 5.8 7.0

CO2High % 9.0 9.0 9.0 9.1 9.1 9.0

CO2Low % 8.5 8.6 8.5 8.6 8.5 8.8

O2High % 4.9 4.9 4.9 4.9 4.9 5.1

O2Low % 5.8 5.8 5.8 5.8 5.8 5.8

3.2.2 Propane G31

Speciﬁcation Unit Propane

Nominal supply pressure mbar 30-50

Supply pressure (min. - max.) mbar 25-50

Gas category - I3P

Class - B23, C13, C33

Speciﬁcation Unit XR10 XR20 XR30 XR40 XR50 XR60

Gas consumption (max.) m3/h 1.1 1.8 2.5 3.5 4.4 5.3

CO2High % 11.1 10.8 10.6 10.8 10.8 10.3

CO2Low % 10.7 10.3 10.0 10.2 10.3 9.9

O2High % 4.7 4.7 4.7 4.7 4.7 5.0

O2Low % 5.7 5.7 5.7 5.7 5.7 5.7

3.3 Dimensions

The dimensions of this air heater can be found in ﬁgures 1 and 2.

490

245

285

495

575

85106

680

M10

110

Figure 1 - Dimensions of the XR10-XR30

150

650

70546

400

670

495

140150

106

M10

105

120

Figure 2 - Dimensions of the XR40-XR60

INSTRUCTION MANUAL AIR HEATER TYPE XR

4 Installation

4.1 Preparation

Before installation, please use the data badge to check:

• if the heater is in accordance with the order;

• if the heater is suitable for the local present

provisions (gas type, gas pressure, electrical supply

etc.)

Before leaving the factory, the air heater has been tested

for safety and has been set to the operating settings. It has

been conﬁgured for the type of gas that is stated on the

data badge. Should there be any doubt about the settings

that apply to your situation, please contact your supplier.

4.1.1 Standards

NOTICE The installation must comply with all applicable

local and national standards.

NOTICE The air heater must be installed in accordance

with the relevant requirements of the Gas Safety

regulations, Electrical installation regulations and or other

local regulations that may apply.

For United Kingdom only:

NOTICE The air heater must be installed in accordance

with the relevant requirements of the Gas Safety

regulations, Electrical installation regulations and or other

local regulations that may apply (e.g. The Institute of Gas

Engineers IGE UP-1 and 2, BS6230, BS5440 building

regulations and the IIE regulations that incorporate the gas

safety regulations).

4.2 Positioning the air heater

Keep the following requirements in mind when choosing a

location to install your air heater:

WARNING! Never install an air heater close to ﬂammable

materials.

• Keep sucient distance between the heater and

any obstructions. This is both for safety reasons

and to allow access for service and maintenance

(ﬁgure 3).

• Make sure the air ﬂow to and from the heater is

free from obstacles at least 5 metres in front of the

heater. Also make sure the air intake is free from

obstacles.

• Make sure enough space remains to open the door

of the air heater.

• Make sure the wall can support the air heater.

• Ensure sucient clearance distance for the ﬂue

system.

Figure 3 - Minimum clearances around the air heater

4.2.1 Orientation

• When the heater is not installed horizontally, re-

adjust the CO2setting from the gas valve.

• If the air heater is installed with the air stream

vertically downwards, maintain a maximum

suspension height of 8 meters to ensure that warm

air will reach the ﬂoor.

Depending on the model of your air heater, ﬁve types of

wall support can be used:

Model(s) Wall support Art. Nr.

XR10 - 30 Standard GA8610

XR40 - 60 Standard GA8620

XR10 - 30 Turnable* GA8630

*can be rotated horizontally or forward.

Model(s) Wall support Art. Nr.

XR10 - 60 Vertical suspension kit GA845

XR10 - 30 Suspension adapter GA8690

Figure 4 - Wall support (standard)

Figure 5 - Wall support (turnable)

Figure 6 - Vertical suspension kit

Figure 7 - Suspension adapter

The air heater is equipped with threaded sockets to

suspend the unit (see §11).

• Use the suspension kit that is compatible with your

air heater. The suspension kit is not delivered with

the air heater. Contact your supplier.

INSTRUCTION MANUAL AIR HEATER TYPE XR

4.3 Gas type & connection

The unit is suited for the use of natural gas or propane gas.

The speciﬁc gas type that a heater is set up for can be

found on the packaging labels and on the heater badge.

The heater can be converted to another gas type. Contact

your supplier for more information.

The working and standing supply pressure must be

a minimum of 17 mbar, and a maximum of 50 mbar,

measured at the inlet pressure nipple of the gas control in

the heater.

NOTICE The supply line’s manual isolation valve must be

placed within reach of the heater.

NOTICE All gas supply lines must be mounted without any

mechanical tension.

NOTICE Always clean the inside of a gas supply line

before connecting it to the air heater. Place a gas ﬁlter in

the supply line when needed.

CAUTION! When using pressures above 60 mbar to test

the supply lines, always close the manual isolation valve of

the air heater.

For United Kingdom only:

The supply line for gas must comply with the Gas

Engineers publications UP-1 and UP-2, as well as with BS

6891.

4.4 Electrical connection

The electrical installation must comply with local and

national requirements as well as IEE regulations.

4.4.1 Power supply

The air heater requires an earthed power supply of 230 V/

AC. A supply of 400 V/AC + Neutral is optional. The control

circuit is a two wire low voltage bus communication.

Figure 8 - The air heater's connection clamps

• Connect the wires of the mains cable to the clamps

in the connection box (ﬁgure 8).

• Completely isolate the air heater for maintenance

purposes. Use an isolation switch (min. 3 mm

contact opening gap), a power plug or a non-

switched fuse spur. See the electrical wiring

diagram in §11.

4.4.2 Fuse

One fuse is present on the air heater’s control board (see

the electrical wiring diagram in §11).

• When replacing this fuse, always use one of the

same type (5AT).

4.5 Room thermostat

The heater can only be controlled with one of the following

Winterwarm modulating room thermostats:

• The MTS: a modulating digital thermostat.

• The MTC: a modulating digital clock thermostat

with optimiser.

• Interface module; a specially designed interface

module for BMS systems. Contact your supplier for

more information.

• ON/OFF thermostat: a simple on/o thermostat.

WARNING! Never use a room thermostat to interrupt the

electric power supply to the heater.

4.5.1 Installation requirements

Following these requirements when placing the thermostat

to ensure the heater functions correctly:

• Make sure that air can circulate around the

thermostat.

• Make sure the sun does not shine directly upon the

thermostat.

• Do not place the thermostat on a cold wall.

• Place the thermostat on an inner wall free from

draught.

• Never place the thermostat within the throw of the

heater.

• Never mount the thermostat near the aerials of

internal communication networks. These emit

radiation that can disturb the thermostat. Keep

several meters distance.

In all cases, the communication between the heater

and the thermostat is based on a two wire, low-voltage

connection. (see the electrical wiring diagram in §11).

Follow these instructions to prevent malfunction of the

installation and damage to the thermostat or air heater:

• Use a cable with the following speciﬁcations:

–Signal cable.

–Shielded and twisted.

–Minimum dimensions: 1 x 2 x Ø0,8 mm2.

–Maximum length: 200 m.

CAUTION! Keep the thermostat cable separated from the

mains cables.

CAUTION! Connect the cable’s earth shield only to the

earth terminal inside the air heater. Do not connect the

other end of the cable’s earth shield.

NOTICE A cable with a thickness of less than 0.8 mm will

result in a poor signal.

NOTICE A cable that is not shielded and twisted may

result in a disturbed communication in an EMC-unfriendly

environment.

4.5.2 Modulating room thermostat installation

To connect the air heater to an MTS or MTC thermostat, do

the following:

1. Connect the two control wires to terminals 4 and

5 (see ﬁgure 9 or the electrical wiring diagram in

§11).

a. Set the S1 and J14 switches on the control

unit as follows (ﬁgure 10/11):

b. Set S1 to 1.

c. Set J14 to 1.

NOTICE The air heater must be switched o when setting

the switches. Otherwise the settings will have no eect.

Figure 9 - Modulating thermostat connection

1 2 3 4 5 6 7 8

1 0

S1 J14

Figure 10 - Positions of the S1 and J14 switches

Figure 11 - Location of the S1 and J14 switches

4.5.3 Installation of multiple heaters on one control unit

An MTC or MTS room thermostat, or interface module can

control up to 8 air heaters. To connect the air heaters, do

the following (ﬁgure 12):

NOTICE This functionality does not apply to an ON/OFF

thermostat.

1. Connect the two wires of the thermostat to termi-

nals 4 and 5 of the ﬁrst air heater.

2. Connect the ﬁrst air heater to the second air heater.

3. Repeat for each subsequent air heater.

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