Winterwarm DXE80 Gas Fired Warm Air Heater Installation Guide

Winterwarm DXE80 Gas Fired Warm Air Heater

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.

Symbols used in this manual

• WARNING! Indicates a potentially dangerous situation that could lead to death, severe injury or serious product damage.
• DANGER! Indicates a dangerous situation that would lead to death or severe injury.
• 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.

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.

Safety instructions

Always follow the safety instructions in this chapter when installing, using or performing maintenance on this air heater:

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.

Protection against dust
CAUTION! Cover the air heater while spreading sawdust on the floor. This prevents large amounts of dust from accumulating on the heater.
CAUTION! The air heater can be used in a dusty environment (e.g. a poultry shed) if they are cleaned and maintained more frequently.

Temperature
CAUTION! Do not install the heater in places where the temperature can rise above 40°C. Higher temperatures cause the internal components to degrade much faster.

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.

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.

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.
CAUTION! Air heaters installed in a dusty and/or wet environment must be maintained and cleaned more frequently.
CAUTION! Air heaters installed in poultry sheds must be maintained and cleaned after every breeding cycle.

Protection from water (IP class)
WARNING! Never use water when cleaning electrical parts. This air heater is protected against splash water and has an IPX4D classification.
WARNING! Do not use a pressure washer to clean parts that contain electronics, such as the electric motor or the machine cover.

Disinfecting fluids
CAUTION! Some aggressive disinfection fluids can damage the heater. When using such fluids, cover the heater while disinfecting the shed.

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.

Technical specifications

Performance

Gas types

Natural gas G20

DE: II2ELL3B/P BE: I2E(s), I2Er FR: II2Er3B/P

PL: II2ELwLs3B/P

Class| –| B22, C12, C32
Specification| Unit| DXE80| DXE100
Gas consumption (max.)| m3/h| 8.8| 11.4
Burner injectors| n x Ømm| 6x 3.7| 8x 3.7
Burner pressure high| mbar| 7.4| 7.7
Burner pressure low| mbar| 3.2| 3.5
CO2 High (indication)| %| 8.3| 8.3

Propane

DE: II2ELL3B/P BE: I3P

FR: II2Er3P

PL: II2ELwLs3B/P

Class| –| B22, C12, C32
Specification| Unit| DXE80| DXE100
Gas consumption (max.)| m3/h| 6.6| 8.6
Burner injectors| n x Ømm| 6x 2.3| 8x 2.3
Burner pressure high| mbar| 19.5| 18.5
Burner pressure low| mbar| 8.1| 8.5
CO2 High (indication)| %| 9.2| 9.5

Butane / LPG

DE: II2ELL3B/P BE: I3B/P

FR: II2Er3B/P

PL: II2ELwLs3B/P

Class| –| B22, C12, C32
Specification| Unit| DXE80| DXE100
Gas consumption (max.)| m3/h| 5.0| 6.5
Burner injectors| n x Ømm| 6x 2.3| 8x 2.3
Burner pressure high| mbar| 15.0| 14.5
Burner pressure low| mbar| 6.0| 6.5
CO2 High (indication)| %| 9.2| 9.2

Dimensions
The dimensions of this air heater can be found in figure 1.

Installation

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.

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).

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 sufficient distance between the heater and any obstructions. This is both for safety reasons and to allow access for service and maintenance (figure ).
• 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 sufficient clearance distance for the flue system.

Orientation

• Install the heater horizontally without an inclination (figure 2).

Suspension

Gas type & connection

The unit is suited for natural gas, propane or butane (LPG). 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.

Electrical connection
The electrical installation must comply with local and national requirements as well as IEE regulations.

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.

• The heater must be electrically isolated during servicing. 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..

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).

Room thermostat

• by an ON/OFF signal;
• through a bus communication system with an external interface.

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.

Bus communication system installation
To connect the air heater to a bus communication system, do the following:

1. Connect the two control wires to terminals 4 and 5 (see figure 4 or the electrical wiring diagram in § 11.).
2. Set the S1 and J14 switches on the control unit as follows (figure 5 / 6):
   • Set S1 to 1.
   • Set J14 to 1.

NOTICE The air heater must be switched off when setting the switches. Otherwise the settings will have no effect.

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 7):

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.

Each air heater needs an unique number to be recognised by the room thermostat. This number can be set with the J14 switch on the control unit of each air heater:

1. Set the S1 and J14 switches on the control unit as follows (figure 8):
   • Set the S1 switch of the first air heater to 1.
   • Set the S1 switch of the other air heaters to 0.
   • Set the J14 switch of the first air heater to 1.
2. Set the J14 switch of the second air heater to 2, etc.

NOTICE If the J14 switch of more than one air heater is set to the same number, the system will not work.

NOTICE The air heater must be switched off when setting the switches. Otherwise the settings will have no effect.

ON/OFF thermostat installation
To connect the air heater to an ON/OFF room thermostat, do the following:

• Connect the two thermostat wires to terminal 6 and 7 (see figure 9 or the electrical wiring diagram in § 11.). This is a 24 V connection for the thermostat signal.

NOTICE Never combine these connections with the terminals 6 and 7 of other air heaters.
NOTICE Always use separate relays for each air heater.
NOTICE Do not connect an external power source to these terminals. These terminals need a dry contact.

Flue systems

The air heater is equipped with an internal combined combustion air supply and a combustion gas outlet device (wall terminal). Only in this configuration is the installation is CE approved. Do not change this configuration. See the installation drawings for more information.

CAUTION! Never connect another terminal to the air heater. Always consult the manufacturer or its representative.

Operating the air heater

Burner cycle
The air heater’s display shows the current status of the burner cycle (figure 10).

System fan cools the heat exchanger.

| 60 – 120
P| Anti-shuttle| The heater can not generate a heat demand during this period.| –
F| Ventilation| Request to start (summer) ventilation mode.| –

Manual operation

1. Press and hold the (+) and (-) buttons for 1 second to enter the manual mode.
2. Press the (+) or (-) button to select the value of a system test mode.
3. Press the OK/RESET button to save the system test mode or press the RETURN button to cancel the mode selection.

requests.
6| Requests off| The system is inactive and does not accept RT or 0-10 V input requests.
7| 12-hour heat| The heater burns for 12 hours at a high power.
8| Interruptible ventilation| Sumer ventilation is activated. It can be interrupted by RT or 0-10 V input requests.

Minimum firing time
The heater will always fire for a minimum of 1 minute, even if the heat demand stops. This is to avoid a large amount of start and stops.

NOTICE The heater will try to ignite 2 times before it stops and gives an error.

Summer ventilation
The fan can be set to run in the summer. Follow the instructions in the user manual of the special Room thermostat.

Overheating protection
The air heater’s heat exchanger and flue system are both protected from excessive temperatures.

Heat exchanger
An NTC sensor is located near (or on) the heat exchanger. This sensor monitors the heat exchanger temperature. If the heat exchanger becomes too hot, this sensor will cause the heating process to stop. Depending on the temperature, the air heater performs the following actions:

• Step 1: Power reduction (when possible).
• Step 2: Burner stop, followed by an automatic restart when cooled down (display: E05 / E36).
• Step 3: Burner stop, followed by a Lock Out. A manual reset is required. (display L15).

NOTICE A manual reset can be done on the electronic circuit board or remotely with the special room thermostat.

Flue passage check
The air heater is equipped with a pressure switch that checks the passage of combustion air through the heat exchanger. The pressure switch checks if there is sufficient movement of combustion air through the heat exchanger. If the pressure difference is too low, the air heater will stop. Error L-14 will be shown on the display.

Commissioning the air heater

Adjusting the settings
Prior to packaging, the safety and functioning of each air heater is checked in detail. It is also set to the right combustion efficiency. In general, the heater does not need to be adjusted after installation. It is only necessary to perform a functional check and to obtain a flue gas analysis and record it for later reference.

• CAUTION! Use only calibrated instruments to adjust the air heater.
• CAUTION! Never carelessly turn the adjuster screws.
• NOTICE Adjusting the control without a supporting flue gas analysis voids the warranty. Only adjust the burner pressures if they differ more than 0,5 mbar from its setting.

Commissioning the air heater
Once the unit is installed according to this manual, the unit can be commissioned. To do so, follow these instructions:

1. Make sure the gas supply pipe is clean, gas tight and free from air.
2. Switch on the electric supply with the maintenance switch. You are now able to observe the first start-up and become familiar with the functioning of the heater.

NOTICE If the gas line is not purged correctly, the heater will attempt to start twice before going into a lock-out condition. In this case, manual reset is necessary.

1. Instruct the end user of the about a safe use of the air heater:
   • The presence of gas
   • The location of the manual gas valve
2. Instruct the end user about the operation of the heater:
   • Lock-out indication
   • Reset
3. Instruct end user about the necessary maintenance.
4. Leave this manual with the end user.

First use – thermostat
To commission the air heater via the room thermostat, do the following:

• Put the thermostat in the highest position. The start sequence is always the same. The air heater will burn for the minimal firing time (see §6.3. for more information).

First use – display
To commission the air heater via the display’s manual test mode, do the following:

NOTICE The display’s manual test mode will only work for maximum 10 minutes.

1. Press and hold the Return and (–) button for a few seconds (figure 11). The display will alternate between Lo and St. This means the heater will start up in Low fire.
2. Press the (+) and (–) buttons to toggle between Low and High fire (figure 11).
3. Press the (–) button until 0 is displayed to exit the service. The air heater will always cool down the heat exchanger for several minutes.

The test mode will automatically end after 10 minutes.

Combustion settings

In principle, it is not necessary to adjust the control shortly after commissioning the air heater. When the control does have to be adjusted after a period of use or after installing a new heater, this must be done by a qualified person using calibrated equipment.

DANGER! A poor adjustment can lead to overheating of the air heater and/or production of toxic carbon monoxide.

Adjusting the burner settings
The flow of gas to the burner is controlled with a gas valve. The valve must be set to a high and a low burner pressure. To adjust the burner pressures, do the following:

1. Look up the correct burner pressures (see §3.2.).
2. Remove the cover from the gas valve. Use a (small) screwdriver.
3. Switch on the air heater on high fire (see §6.1.).
4. Set the high burner pressure by turning the outside of the adjuster screw. Use a 10 mm wrench.
5. Set the air heater to low fire.
6. Set the low burner pressure by turning the inside of the adjuster screw. Use a screwdriver.

NOTICE Do not set the burner pressure lower than 3 mbar. This avoids problems with cross-lightning of the burner.
NOTICE Because the high and low burner pressures influence each other, always check both burner pressures at least twice after any adjustment.

DANGER! Always measure the air heater’s CO production. Too much CO usually means the gas mixture is too rich. Adjust this if necessary with the two adjusters (figure 12).

Converting to another gas type

CAUTION! For safety reasons, the manufacturer recommends that the air heater is converted to another gas type only by the manufacturer, its representative or a qualified service technician. Contact your supplier for more information. To convert the air heater to another gas type, the gas injectors on the burner unit have to be changed. A conversion kit is available for this:

1. Switch off the air heater.

2. Shut off the gas and electricity.

3. Disconnect the ignition and ionisation cables from the burner unit.

4. Disconnect the burner manifold from the gas valve. This is a clamp coupling.

5. Unscrew the screws that attach the burner mani-fold to both ends of the endplates of the burner unit.

6. Remove the burner manifold.

7. Remove the gas injectors from the burner tube.

8. Select the correct injectors (see §12.).
   NOTICE The injectors have a stamp that corresponds to the diameter of the injector. For example, 130 means 1.30mm and 210 means 2.10mm.

9. Apply the sealing paste from the conversion kit on the threads of the injectors.
   CAUTION! Avoid paste from getting into the injectors.

10. Insert the new gas injectors.

11. Reattach the burner tube to the burner unit.

12. Mount the burner unit back into the air heater and reconnect all cables.

13. Expel air from the piping and check the gas valve and supply line for leaks.

14. Change the labels on the air heater with ones that have the correct values for the new gas type.

15. Attach an Attention sticker that notifies users that the air heater has been converted to another gas type.

16. Set the burner pressures (see §8.1.).

Troubleshooting

If the air heater malfunctions, first check if the problem is caused by external circumstances (e.g. no supply power). If the problem is not caused by external circumstances, use the tables and instructions in this chapter to fix the air heater.

NOTICE Please remember the built in waiting times of the air heater; the signals of the LED’s and the code on the display. Do not react too soon.

Volatile lock outs
The table below describes the volatile lock outs that can occur. These can only be reset by hand.

11
L-15| Overheating| Heat exchange sensor is overheated| 3
L-17 to 19| Internal error| Internal error| 13
L-20| Flame error| Flame detected after closing the gas valve| 15
L-21| Flame error| Flame detected before opening the gas valve.| 16
L-22| Flame error| Flame failure during burning| 5
Display| Error type| Description| Case #
---|---|---|---
L-25| Sensor error| Heat exchange sensor failure| 4
L-27 to 31| Internal error| Internal error| 13
L-32| Sensor error| Heat exchange sensor failure| 4
L-33 to 38| Internal error| Internal error| 13
L-43| Overheating| Heat exchange sensor is overheated too often| 3

Temporary errors
The table below describes the temporary errors that can occur. These will disappear automatically after the cause has been resolved.

4
E-27 and 28| Heat exchanger sensor error| Heat exchanger sensor short-circuit| 4
E-34| Reset button error| Too many reset actions in a short timespan| 9
E-36| Overheating| Heat exchange sensor is overheated| 3
E-38 and 39| Heat exchanger sensor error| Heat exchanger sensor not detected| 4
E-47 and 48| Heat exchanger sensor error| Heat exchange sensor short-circuit| 4
E-49 to 64| Internal error| Internal error| 13
Display| Error type| Description| Case #
---|---|---|---
E-65| Voltage too low| Supply voltage is too low for over 1 minute|
E-66| Voltage too high| Supply voltage is too high for over 1 minute|
E-67| Pressure switch error| Too many pressure switch errors| 11
E-69| Configuration error| Heater configuration error| 19

Warnings
The table below describes the temporary warnings that can occur. The heater may still be working, or stops until the cause has been resolved.

Instructions
After identifying the problem, use the Case number to find the possible cause in this paragraph.

Case 1: Flame lasts only 5 seconds after ignition.

• The flame is not detected:
  • Check the ignition/ionisation cable and the electrode. The cable should have a resistance of 1 kΩ.
  • The air heater is not earthed properly.
  • The circuit board is defective.

Case 2: No flame after ignition.

• There is not enough gas pressure.
• The gas mixture is too poor:
  • Adjust the gas valve (see §8.1.).
• The gas valve does not open:
  • During ignition, check for a 230 V voltage on the valve.
• Check if the ignition electrode sparks. If not:
  • Check the cable and electrode and replace  them when damaged.
  • Check the burner control unit and replace it  when it does not give a spark output.

Case 3: Heat exchange sensor or flue sensor is overheated.

• Check if the connectors J12 and J6 are plugged in correctly and if the connection J12[1-4] (optional overheating protection) is closed.
• Check if the system fan supplies enough air.
• Check the settings of the gas valve. The heater may be overfired. If so:
  • Adjust the burner pressure.

Case 4: Heat exchange sensor or flue sensor not detected, or short circuit.

NOTICE L-25 refers to the heat exchange sensor. L-26 refers to the flue sensor, if applicable.

• The heat exchange sensor consists of two internal sensors. The readings of these sensors may differ too much:
  • Measure the resistance of each sensor. The resistance should be 20 KΩ at 25 °C and 25 KΩ at 20 °C.
  • If the measured values differ too much, replace the sensor.

Case 5: Too many flame failures while burning.

• The gas supply is not constant. This results in a drop in gas supply pressure while burning and causes the flame to extinguish.
  • Check the gas supply pressure while the heater is burning.
• The burner pressure for Low fire is too low. This causes the flame to extinguish because it is too small to be detected.
  • Check the burner pressure at Low fire and adjust if necessary (see §8.1).
• Recirculation of flue gas. Due to a problem with the flue terminal the flue gas is sucked back into the air inlet. This results into a lack of oxygen and causes the flame to stop.
  • Check the flue system and fresh air supply. Only certified, original parts should be used.

Case 9: Too many reset actions in a short timespan.

• This error will disappear after some time or if the main power is disconnected for a while.

Case 11: Insufficient air passage through the heat exchanger. Pressure switch does not close.

• Check if the combustion fan is running.
• Check if the flue system is blocked or restricted.
• Check the pressure switch and the connections.
• Check the heat exchanger for flue leakage.

Case 12: E-error for more than 24 hours.

• Switch the air heater off and on and check the error code.

Case 13: Internal error.

• Isolate the electrical supply and reenergise. If this does not help:
  • Replace the burner control unit.

Case 14: Pressure switch is closed in stand-by mode.

• Check if the contact is stuck. If so:
  • Replace the pressure switch.
• Check if there is water in the hose. If so:
  • Dry the hose.

Case 15: Flame detected after closing the gas valve.

• Check if the gas valve closes too slow. If so:
  • Replace the gas valve.
• Check if the ionisation electrode is wet. If so:
  • Dry, clean or replace the electrode.

Case 16: Flame detected before opening the gas valve.

• Check if there really is a flame before ignition. If so:
  • Replace the gas valve.
• Check if the ionisation electrode is wet. If so:
  • Dry, clean or replace the electrode.

Case 19: Heater configuration error

• The heater does not know which program to run, due to a mismatch between the burner control unit and the display. If so:
  • Contact your supplier.

Further troubleshooting
When the air heater does start but shows a different problem than described above, check if the following problems apply.

Explosive ignition and/or frequent flame failures

• Check if the gas control settings are correct (see §8.1). A correct CO2 value is important for a proper ignition.
• Check the ignition cable. It should have a resistance of 1 kΩ.
• Check the position of the ignition electrode. The spark has to be formed between the two electrodes, not between the electrode and the burner.

Maintenance

• CAUTION! The air heater must be inspected and cleaned once a year by a qualified installer with sufficient knowledge about the device.
• CAUTION! Sufficient maintenance is critical in circumstances such as high humidity, dust, high switching on/off frequency, etc.

Preparation
Before performing maintenance on an air heater that is already installed, do the following:

1. Set the thermostat to the lowest setting.
2. Close the manual gas valve.
3. Turn off the power supply to the air heater using the maintenance switch.

• CAUTION! Always check for gas leaks after working on the air heater.
• CAUTION! Do not use water when cleaning the air heater.
• CAUTION! The heater must be electrically isolated during servicing. Water can be used to clean the air heater.
• CAUTION! Only the heat exchanger can be cleaned with a pressure washer. Do not use a pressure washer on the following parts:
• The big fan motor on top of the air heater.
• The electronics housing.
• The temperature sensor in the front part of the air heater.

Basic maintenance
To perform basic maintenance on the air heater, do the following:

CAUTION! When cleaning parts of the air heater, use a dry cloth, brush, compressed air or a vacuum cleaner. Never use a steel brush.

1. Inspect the outside of the heat exchanger.
2. Clean the fan guard on the outside of the heater. Clean the fan blades if required.
3. Open the access panel.
4. Clean the inside of the air heater. Focus on the fol-lowing parts:
   • Body
   • Fan blades and motor
   • Heat exchanger
   • Temperature sensor
   • Vane switch (if present)
5. Check if the wiring, nuts and bolts are properly secured and tightened.
6. Grease any parts and bolts that are regularly loos-ened for maintenance.
7. Open the manual gas valve in the supply line and check if the supply lines are air tight, do not leak and do not contain air.

Some checks can only be performed when the heater is running. Do the following:

1. Reconnect the air heater to the power supply.
2. Switch on the air heater.
3. Check if the heater operates without problems. See § 9. if any errors occur.
4. Check the air heater’s combustion efficiency. If necessary:
   • Adjust the burner settings (see §8.1.).

Maintenance of the burner unit
The burner unit is an important part of the air heater and requires special maintenance.

To perform maintenance on the burner unit, do the following:

1. Disconnect the ignition and ionisation cables from the burner unit.

2. Disconnect the burner manifold from the gas valve. This is a clamp coupling.

3. Remove the burner assembly from the air heater,

4. Check the burner for damage, corrosion and alignment of the separate burners.

   • Clean with a brush.

5. If necessary, clean the electrodes.
   CAUTION! Do not twist the electrode out of shape.

6. Check the inside of the heat exchanger for dirt and or damage. If necessary:

   • Clean the heat exchanger.

7. Disassemble the motor part from the flue fan. The housing can remain on the heater.

8. Clean the inside of the flue fan.

9. Check the air supply and the flue discharge for dirt and clean it.

10. Reassemble the burner unit. If necessary:

    • Use new gaskets.

Extensive maintenance in poultry sheds

• WARNING! Air heaters that are used in poultry sheds must be cleaned and inspected after every clean-out, before disinfection and the spreading of sawdust on the floor.
• CAUTION! The heat exchanger can be cleaned with a pressure washer. Do not use a pressure washer to clean parts that contain electronics, such as the electric motor or the machine cover.

1. Use compressed air or a soft brush to clean the remaining parts from the air heater. Focus on the following parts:
   • The inside and outside of the body.
   • The fan blades and motor.
   • The temperature sensor.
2. Remove all dust from the motor. Accumulated dust acts as insulation and can cause the motor to overheat.
3. Use a brush to remove any baked on dust.
4. Clean the burner unit (see §10.2.).
5. Switch on the air heater and let it heat for a while. This burns off any remaining dust particles.
6. Stop the heating process.
7. Cover the air heater when it is fully cooled off. This protects it from dirt or dust.
8. Make sure the air heater is electrically isolated.
9. Disinfect the poultry shed and spread the sawdust.
10. Remove the cover from the air heater. The heater is ready to be used.

Electrical wiring diagram

A complete electrical wiring diagram is shown in figure 14. The connections that are most important to the installation process are shown in figure 15.

Exploded view and spare parts

The parts of the air heater are shown in an exploded view in figure 16. The table below describes each part and shows the correct article number for a replacement part.

Disposal and recycling

The meaning of the symbol on the material, its accessory or packaging indicates that this product shall not be treated as household waste. Please, dispose of this equipment at your applicable collection point for the recycling of electrical and electronic equipments waste. In the European Union and Other European countries which there are separate collection systems for used electrical and electronic product. By ensuring the correct disposal of this product, you will help prevent potential hazards to the environment and to human health, which could otherwise be caused by unsuitable waste handling of this product. The recycling of materials will help conserve natural resources. Please do not therefore dispose of your old electrical and electronic equipment with your household waste.

Declaration of conformity

Winterwarm Heating Solutions B.V. Industrieweg 8 7102 DZ, Winterswijk The Netherlands

Declares that air heater types:

• DXE80 and DXE100
  • CE PIN: 0063BR3344

Are in accordance with the essential requirements of the relevant EU directives, being:

• 2016/426/EU (GAR) relating to appliances burning gaseous fuels
• 2014/35/EU (LVD) relating to the electric safety of appliances
• 2014/30/EU (EMC) relating to electromagnetic compatibility of appliances
• 2006/42/EG (MD) relating to the safety of machinery

Goods should be installed and used in accordance with our instructions and with the applicable local and international rules. Installation should be done by an authorized, qualified and competent installer.
Winterswijk, July 1st 2019

Ir. M. Fiselier Manager Research and Development

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