BMM Heaters BMG, User And Installation Manual

Page 1: ...Air Heater Manuals User Installation Servicing BMM Heaters Ltd 1 Copeland Court Forest Grove Middlesbrough TS2 1RN Tel 01642 240700 Fax 01642 240708 Sales bmmheaters co uk 1 ...

Page 2: ...VG Vertical heater for ducted or AHU applications suitable for natural gas BMGVF Free standing nozzle head heater with force draught gas burner BMGDF Free standing ducted heater with force draught gas burner BMGF Horizontal ducted heater with force draught gas burner BMGDD Downward discharge heater with force draught gas burner 2 ...

Page 3: ... Overheat Protection Device 10 Section 8 Flue System 11 Section 9 Ventilation Requirements 16 Section10 Gas Piping 17 Section 11 Condensate Drains 19 Section 12 Electrical Connections 19 Section 13 Heater Controls 21 Section 14 Commissioning 23 Section 15 Servicing 32 Section 16 Removal and Replacement of Parts 37 Section 17 Spare Parts 39 Section 18 Troubleshooting 40 Section 19 Users Manual 41 M...

Page 4: ...mbustion are directed into a heat exchanger and from there to an external flue which discharges into the atmosphere Factory Test All heaters produced by BMM Heaters Ltd will be subjected to various tests before they are dispatched Each heater is individual so the data will differ between each unit The relevant data can be found on the data plate attached to the heater External Heaters The construc...

Page 5: ... information for service engineers at a later date Section 3 Installers Responsibilities To install the heater as well as the gas and electrical supplies in accordance with applicable specifications and codes BMM Heaters recommends the installer contact a local Building Inspector Fire Officer or Insurance Company for guidance To use the information given in the manual together with the local and n...

Page 6: ... 228 147 2 58 2 58 188 147 4 18 17 4 204 200 246 228 176 3 19 5 17 225 176 5 23 21 8 204 200 420 384 205 3 75 5 17 263 205 6 1 25 4 254 250 420 384 235 4 23 5 17 300 235 6 98 29 1 254 250 420 384 264 4 75 5 17 338 264 7 85 32 7 254 250 420 384 293 5 17 5 17 376 293 8 71 36 3 254 250 420 384 352 6 23 6 23 451 352 10 32 43 304 300 1704 1364 440 8 46 10 34 537 440 13 08 54 5 304 300 1704 1364 513 9 4...

Page 7: ...ns or insurance company s requirements appertaining to the area in which the heater is located particularly where special risks are involved such as areas where petrol vehicles are housed where cellulose spraying is carried out in wood working departments etc Clearances and Positioning The following clearances for installation and servicing must be observed To the front Equal to the depth of the h...

Page 8: ...d to be installed within an Air Handling Unit or ductwork The appliance is designed to work in a maximum ambient temperature of 40 c The Air Heaters are mounted direct on the floor and do not need any fixing The base on which the heater is positioned should not be less than 150mm 6 inches thick and must be constructed of non combustible material Any combustible material adjacent to the heater and ...

Page 9: ... return air intake and the warm air outlet s should therefore be fully ducted in the plant room to and from the heater respectively The openings in the structure of the plant room through which the ducting passes must be fire stopped In addition where there is a risk of combustible material being placed close to the warm air outlets suitable barrier rails should be provided to prevent any combusti...

Page 10: ...sis it must be investigated by a competent registered engineer as this could cause serious damage to the heater WARNING If the heater has a Honeywell combined thermostat installed then the jumper link must be removed from the replacement thermostat Heat exchanger damage may be the result Failure to follow these instructions can result in death injury property damage or product damage Honeywell ove...

Page 11: ...n e This appliance does not require a draught diverter f BMM Heaters recommend that a 90º Tee condensate piece is connected directly onto the heater spigot from this point the flue must then rise vertically with no horizontal runs of flue pipe or 90º bends If there is an unavoidable obstruction then the use of 45º bends will be permitted Please contact BMM Heaters if more that two 45º bends are us...

Page 12: ...ide an extraction effect under virtually all wind conditions the free area of outlet openings should be at least twice the nominal area of the flue Outlet openings should be provided preferably all round or at least on opposite sides It is important for the terminal of an individual open flue system to be located so that it is not likely to be subjected to wind pressures which could restrict or re...

Page 13: ...f intersection see figure 3 See figure 3 Pitched Pitch not exceeding 45 At or above roof level see figure 4 600mm above flue roof intersection see figure 4 Flat With parapet 600mm above flue roof intersection see figure 6 Without parapet Not applicable 250mm above flue roof intersection see figure 10 The base of the terminal to be 600mm above the level of the adjacent roof edge see figures 1 6 and...

Page 14: ... termination Not less than 600 mm Termination on ridge Fig 3 Pitched roof exceeding 45 Greater than 45 Not less than 1000 mm Not less than 1000mm Dormer window Fig 2 Pitched roof within 1 5 m of a structure on roof Not Less than 600mm Less than 1500 mm Terminals must not be positioned within 1 5m of the wall surface Not less than 600 mm Not greater than 45 Fig 1 Pitched roof not greater than 45 No...

Page 15: ... less than 600 mm Parapet Fig 9 Flat roof with flue close to parapet Fig 10 Flat roof with no parapet Not less than 250 mm Not less than 600 Greater than 10 h1 Greater than 10 h2 h2 250 mm h Structure Structure Fig 7 Flat roof envelope method Less than 10 h2 Greater than 1500 mm h2 Structure h Structure Not less than 600 mm Not less than 600 mm Parapet Not less than 600 mm Fig 6 Flat roof with par...

Page 16: ...tance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour Grilles or louvers should be designed so that high velocity air streams do not occur within the plant room The ventilation should be installed to in accordance with local and national codes Ventilation Requirements ...

Page 17: ...rk d All gas pipe work and electrical connections must be adequately supported and must not support any of the heaters weight or rely on the strength of the burner gas pipe work e Unless the heater is suspended or movement is apparent the BMM Heater must be connected with medium heavy or copper pipe otherwise the use of an approved flexible connection between the isolating valve and the heater can...

Page 18: ... BSP 117 1 BSP BSP 147 1 BSP BSP 176 1 BSP 1 BSP 205 1 BSP 1 BSP 235 1 BSP 1 BSP 264 1 BSP 1 BSP 293 1 BSP 1 BSP 352 2 BSP 2 BSP 440 2 BSP 2 BSP 513 2 BSP 2 BSP 586 2 BSP 2 BSP 733 2 BSP 2 BSP 880 2 BSP 2 BSP 952 2 BSP 2 BSP Further Information regarding pipe work to the burner can be found in the burner manual attached to this document 18 ...

Page 19: ...o the mains electricity supply should allow complete electrical isolation of the heater and the supply should serve the heater only The mains isolator should be provided adjacent to the heater in an easily accessible position The isolator must have contact separation of at least 3 mm on all poles The electric and controls terminations are located on the front of the Heater housed in an interface p...

Page 20: ...30 Amps 205 5 5kw N A 20 Amps 5 Amps 30 Amps 235 7 5kw N A 30 Amps 5 Amps 30 Amps 293 7 5kw N A 30 Amps 5 Amps 30 Amps 440 2 x 5 5kw N A 30 Amps 5 Amps 30 Amps 513 2 x 7 5kw N A 30 Amps 5 Amps 30 Amps 586 2 x 7 5kw N A 30 Amps 5 Amps 30 Amps 733 Special Requirements On application 880 Special Requirements On application 952 Special Requirements On application Controls BMM Heaters can supply contro...

Page 21: ...d with the supply fan c T6 is 10v DC signal for modulation d T7 24 volts AC supply for modulating please note the 24 volts transformer is in our panel please advise if you are using external 24 volts e T8 0 volts f T5 240v burner lockout indication if required Please supply 15 minutes supply fan over run on burner shutdown If you require any further information or you have any special requirements...

Page 22: ...0 volts e T5 240v burner lockout indication if required Please supply 15 minutes supply fan over run on burner shutdown If you require any further information or you have any special requirements please do not hesitate to contact our Technical Department WARNING Electrical Shock Hazard Use extreme caution while working on this appliance Failure to follow these instructions can result in death or e...

Page 23: ... are set and diffuser outlets are open to give correct air flow and that the correct number of air by pass blades have been removed to by pass the air in excess of our maximum amount of air through our heater which can be found in Section Minimum and Maximum Air Volumes of this Manual 7 Check with the controls engineer that he has an interlock with the supply fan burner so that the burner can not ...

Page 24: ...ee burner insert in this manual 11 Carry out full emission checks with a flue gas analyser The parameters are to be set as specified in this manual by the adjustment of the burner air damper which when satisfied must be locked off securely 12 The high and low air pressure switch must be set after the damper has been locked off The low air pressure switch is set by turning it up until it locks out ...

Page 25: ...include the following a Model and serial numbers b Heater running temperature and over heat settings c Full thermal input d Governor pressure settings pilot for start gas and main for full fire e Gas flow rates for full fire f Burner damper setting and pressure switch settings g Flame signal strength on full fire h Exhaust gas O CO CO and temperature 19 After setting all air pressure switches and ...

Page 26: ...ater than 75mb static and no less than 17 5mb running 6 Make sure that all dampers are set and diffuser outlets are open to give correct air flow and that the correct number of air bypass blades have been removed to bypass the air in excess of our maximum amount of air through our heater which can be found in the section Minimum and Maximum Air Volumes in this Manual 7 Check with the controls engi...

Page 27: ...goes to low fire and set it in accordance to the rating plate pressure The governor must be throttled down until it takes control of the head pressure and left there The main gas valve throttle can be locked in to position when the gas head pressure is set When you are satisfied with the gas settings then the CPI switch requires setting on the SKP valves they are integral which are factory set For...

Page 28: ...ection test is to be done with leak detection fluid and electronic leak detector on the gas train while the burner is running to see if there are any leaks in the burner gas train and a soundness test is to be done on all gas work 18 Finally make a full record of combustion data on commissioning sheet provided a copy is to be presented to the customer and to BMM Heaters on completion of work The c...

Page 29: ... the inlet pressure is no greater than 75mb static and no less than 17 5mb running 6 Make sure that all dampers are set and diffuser outlets are open to give correct air flow and the correct number of air bypass blades have been removed to bypass the air in excess of our maximum amount of air through our heater which can be found in the section Minimum and Maximum Air Volumes in this Manual 7 Chec...

Page 30: ...f the burner by turning the low speed down The burner fan should slow down and the output should decrease now set the burner to the low head pressure and adjust the low setting to match the air for combustion the readings should be the same For further information see insert or inverter manual for inverter setting in this manual 10 Now plug the burner 0 10v dc back in and connect the 0 10v dc sign...

Page 31: ...17 Finally make a full record of combustion data on commissioning sheet provided a copy is to be presented to the customer and to BMM Heaters on completion of work The commissioning sheet should include the following a Model and serial number b Heater running temperature and overheat settings c Full thermal input d Governor pressure settings pilot for start gas and main for full fire e Gas flow ra...

Page 32: ... exchanger the combustion chamber or in the flue chamber are blocked the Heater can overheat causing the unit to shut down on the overheat thermostat To clean the Heat exchanger The heat exchanger must be cleaned from the front and rear of the appliance after first removing the following items a The burner assembly Burner Removal With gas and electrical supply isolated 1 Disconnect the electrical ...

Page 33: ...eater is housed within an Air Handling Unit there will be sufficient room to allow servicing Servicing as per our standard internal procedures Please note in extreme weather conditions always ensure any electrical connections etc are protected and do not allow water onto them If stand alone external heater there will be a door which is hinged up over to allow protection to the engineer from weathe...

Page 34: ...through both surfaces with a sharp knife to give an exact join Self adhesive webbing is easier to secure available from BMM Heaters Recommended intervals Weekly check Check that there are no apparent leaks Clean air filters if fitted if of the washable type or replace where necessary Quarterly check As weekly check and also Check the tension of the main fan belt s Check the flue for condensation R...

Page 35: ...s running On burner shutdown the supply fan overrun will continue running for 10 15 minutes to dissipate residual heat Fan Assembly Inspect the fan blades to see they are not damaged and that there is no excessive building up of deposits that could give an imbalance via access panel on the side of the heater If necessary clean the fan blades The main fan bearings are permanently sealed and do not ...

Page 36: ...ion is required or the heater repeatedly locks out then a Corgi registered engineer must be called to investigate further Please Note You must not electrically isolate the heater when in full fire always wait until the burner stops and the supply fan over runs to dissipate the heat before electrically isolating For summer ventilation switch on off switch to off and set fan switch from auto to manu...

Page 37: ...uter casing and disconnect wires The wires are held in by spring terminals which will release by pushing a small screwdriver into the slot next to the wiring termination 3 Remove fixing screws which secure stat to front of panel carefully withdraw stat from heater and remove casing 4 Re assemble in reverse order and check settings adjust if required to fan on 35 fan off 25 high limit 90 Supply Fan...

Page 38: ...ote you will require x 4 locking nuts on replacement 6 Re assemble in reverse order 7 Re tighten the supply fan belt until 12mm movement is obtained 8 Check fan rotation is correct Recommend Tools to be used a Spanner 10mm 13mm and 17mm b Screwdriver Terminal medium flat blade and philips medium c Stillsons 14 and 18 d Allen keys standard metric set 1 5mm 10mm e Side cutters pliers f Multi meter g...

Page 39: ...ectrode 101 Flame Probe 102 Please refer to gas burner supplement supplied with this manual All components can be purchased from BMM Heaters WARNING Only use parts recommended by BMM Heaters or other wise stated in this manual You must first contact BMM Heaters if you want to use alternative parts 39 ...

Page 40: ...urner supplement finding chart Overheat trip Dirty filters low supply air Filters supply fan belts damper operations Burner held off No enable signal Check BMS Controls back via T1 T2 in heater interface panel Main fan runs continuously Electrical Summer Winter switch set to summer Manual Fan thermostat set to low Fault Fan Limit stat Main fan Fails to run Electrical Fan Motor faulty Fan Limit sta...

Page 41: ...egistered engineer Corgi you are now able to use your Heater safely Easy Lighting and Shutting Off Instructions Burner Start up 1 Ensure Burner and Heater On Off Switch is on 2 Fan switch is in auto position If the heater is controlled via a BMS then the supply fan should be running before the burner can start 3 Make sure the time clock and thermostats are calling for heat or that the BMS is givin...

Page 42: ... engineer registered with corgi This Heater should not be electrically isolated during normal operation doing so without a fan run on for 10 min will cause serious damage to the heater Simple Fault Finding burner faults If the burner fails to ignition for any reason it will go to lockout This will be indicated by the red light on the burner or digitally shown on a display screen Press in and relea...