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Nortek NRV24M Installation And Operating Manual

Nor-ray-vac modulating; continous radiant tube system
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INSTALLATION AND OPERATING MANUAL
Nor-Ray-Vac
Modulating
Continous Radiant Tube System
WARNINGS
Nortek Global HVAC (UK) Limited equipment must be installed and maintained in accordance with the
requirements of the Codes of Practice or rules in force. All external wiring MUST comply with the codes of practice
or rules in force in the country of installation.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
Read instructions before installing or servicing this equipment. Gas-fired appliances are not designed for use in
hazardous atmospheres containing flammable vapours or combustible dust, containing chlorinated or halogenated
hydrocarbons, or in applications with airborne silicone substances.
Reznor® Is a registered trademark of Nortek Global HVAC, LLC.
ErP
2018
Part No. D301040

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Summary of Contents for Nortek NRV24M

  • Page 1 Continous Radiant Tube System WARNINGS Nortek Global HVAC (UK) Limited equipment must be installed and maintained in accordance with the requirements of the Codes of Practice or rules in force. All external wiring MUST comply with the codes of practice or rules in force in the country of installation.
  • Page 2 Any reference made to Laws, Standards, Directives, Codes of Practice or other recommendations governing the application and installation of heating appliances and which may be referred to in Brochures, Specifications, Quotations, and Installation, Operation and Maintenance manuals is done so for information and guidance purposes only and should only be considered valid at the time of the publication.
  • Page 3 Document Index. 1 Installation Requirements 1.1 Compliance Notices 4 Servicing Instructions 1.2 Certificate of Conformity 4.1 Tools Required 1.3 General Product Information 4.2 Burner Exploded Views 1.4 Model Definitions 4.3 Vacuum Fan 1.5 General requirements 4.4 Radiant Tubes 1.6 Delivery and Pre-Installation Checks 4.5 Tube Couplers 1.7 Health &...

  • Page 4: Installation Requirements

    Introduction. Gas Appliance Directive: (90/396/ EEC) Machinery Directive: (2006/42/EC) Low Voltage Directive: (2006/95/EC) elcome to the range of Nor-Ray-Vac ‘M’ series modulating continuous radiant tube heaters. The Electromagnetic Compatibility Directive: (2004/108/EC) Nor-Ray-Vac ‘M’ series modulating system complies with the Product Liability Directive: (85/374/EEC) requirements of the European Gas Appliance Directive and BS EN777-4.

  • Page 5: Certificates Of Conformity

    The Nor-Ray-Vac ‘M’ series conforms to the following The tube into which the burners are mounted and over harmonised standards: which the reflectors are fitted and emits the maximum heat is called the radiant tube. The radiant heat emitted from the hot tube is directed downwards by reflectors.

  • Page 6: Delivery And Pre-Installation Checks

    If any of these points are not satisfied then contact should recommendations may constitute a hazard. be made with the Sales Office at Nortek Global HVAC (UK) Limited as soon as possible by telephoning 01384 489250. In the case of claims for damage, this must be signed for as...
  • Page 7 Model Horizontal If there are any doubts as to the strength or suitability of NRV24M 4.0M roof steelwork to which heaters are to be suspended, please refer to a Consultant, Architect or owner of the building.
  • Page 8 fig. 1.b Clearance for servicing - distances to walls and obstacles above. B Reflector D Side wall Obstacle above End cap G Burner Lid fig. 1.c Clearance for servicing - distances to obstacles above. B Reflector Obstacle above End cap G Burner Lid Doc No.

  • Page 9: Clearance To Combustibles

    Distance from combustibles (distance from heat source that will produce a 50ºC rise in temperature above ambient of a black surface) A Radiant tube; B Standard reflector; C Combustible material underneath; D Combustible material on side; E Combustible material above; F Perimeter reflector; Burner Model NRV24M NRV32M End Vent In-line...
  • Page 10 Nortek Global HVAC (UK) or repair. Limited and must only be carried out by a qualified/competent gas engineer.

  • Page 11: Electrical Connections

    3mm on all poles and supplying the appliance only. We recommend use of Nortek Global HVAC (UK) Limited approved controls. Please refer to SmartCom control manual for siting and installation details and figures 4.l and 4.m Where alternative controls are used, please refer to the...
  • Page 12 Figure 4.a. Typical Burner Wiring Connections - single leg shown Doc No. 700070 Page 12 of 56...
  • Page 13 1.11.1.1 NRV ‘M’ system - Typical External Diagram Doc No. 700070 Page 13 of 56...
  • Page 14 1.11.1.2 NRV ‘M’ system - Typical External Diagram - Independent Zonal Damper Modulating Doc No. 700070 Page 14 of 56...
  • Page 15 1.11.2 Wiring Details Figure 4.c. NRV M internal wiring diagram - End Vent Burner (EV) MAINS INPUT IGNITOR FLAME SENSOR GRN/YEL BLACK FILTER MAIN J.S.T. BLUE BLUE LAMPS MAINS DELAY TIMER BLUE SOLENOID BURNER VALVE VALVE J.S.T. BLUE POWER OUT BLUE GREEN/YELLOW VACUUM...
  • Page 16 igure 4.e. M internal wiring diagram - End Vent Burner c/w N/O or N/C volt free Lockout contacts MAINS INPUT EMC FILTER IGNITOR FLAME SENSOR GRN/YEL BLACK MAIN RELAY J.S.T. N.O. BLUE BLUE N.C. LAMPS MAINS DELAY TIMER BLUE SOLENOID BURNER VALVE VALVE...
  • Page 17 Figure 4.g. M internal wiring diagram - End Vent Burner c/w 3 way solenoid valve MAINS INPUT IGNITOR FLAME SENSOR GRN/YEL BLACK FILTER 3 WAY AR SOLENOID MAIN J.S.T. BLUE BLUE LAMPS MAINS DELAY TIMER BLUE SOLENOID BURNER VALVE VALVE J.S.T.
  • Page 18 Figure 4.j. NRV Inverter Internal Wiring Diagram for B80, B160 and B300 three phase fans 230V 50HZ 1 Pha SUPPLY MAINS ON LAMP R/L1 S/L2 W/T3 V.S.D.1 TO FAN V/T2 U/T1 FAN HEALTHY LAMP 230V 50Hz 1 Ph Supply 3Ph Supply To Fan Brown Brown...
  • Page 19 Figure 4.l. Alternate NRV Local Relay Unit Internal Wiring Diagram for BH300 three phase fans 415V 50HZ 3 Pha SUPPLY MAINS ON LAMP FAN HEALTHY Contactor TO FAN 415V 50Hz 3 Ph Supply 3Ph Supply To Fan TERMINAL RAIL Doc No. 700070 Page 19 of 56...
  • Page 20 Figure 4.m. NRV M System Schematic interconnecting wiring. B80, B160 and B300 three phase fans. Modulating controlled by SmartCom3 via single phase inverter panel. (single zone shown) Doc No. 700070 Page 20 of 56...
  • Page 21 Figure 4.n. NRV M System Schematic interconnecting wiring. B80, B160 and B300 three phase fans. Modulating controlled by SmartCom3 and zonal branch dampers via single phase inverter panel. (1 zone shown) Doc No. 700070 Page 21 of 56...
  • Page 22 Figure 4.p. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 via three phase inverter panel. (single zone shown) Doc No. 700070 Page 22 of 56...
  • Page 23 Figure 4.r. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 and zonal branch dampers via three phase LRU panel. (1 zone shown) Doc No. 700070 Page 23 of 56...
  • Page 24 Figure 4.s. NRV M System Schematic interconnecting wiring. BH300 three phase fans. Modulating controlled by SmartCom3 and fan damper via three phase LRU panel. (1 zone shown) Doc No. 700070 Page 24 of 56...
  • Page 25 Figure 4.t. Additional wiring for NRV M individual burner lockout SmartCom Mulitizone ! FUSE RATING LIVE 1/L 2/N S/R0S/R1 D0 D1 O0 O1 B1 B0 B2 C2 C0 C1 66 64 20 NEUT Volt Free Mains Volt Free Burner Lockout Voltage To Other Burners Volt...
  • Page 26 fig5.b. Vertical discharge 1.12 Ventilation Requirements Nor-Ray-Vac heaters are installed as flued appliances in accordance with the relevant national requirements in the country of installation. In buildings having an air change rate of less than 0.5 per hour, additional ventilation is required. For detailed information, please see BS6896 section 5.2.2.2.1 Natural Ventilation Low level ventilation openings with a free area of at least...
  • Page 27 1.13.1 Ducted Air Inlet Considerations. ensure that the flexible ductwork is installed to allow for expansion of the heating system. Heat resistant flexible tube is connected to the burner assembly ducted air adaptor and the EVM ducted air On a header duct, the main air supply header which is feed- adaptor and connected to the air supply duct ing the individual branch ducts and burner/end vent supply ducts must have a maximum pressure drop of 0.25 mbar...
  • Page 28 1.14 Vacuum fan mounting details (Type ‘B160’ fan illustrated) Fan Size B160 B300 BH300 A (crs) E (Ø) G (Ø) R (crs) S (crs) 3596 Doc No. 700070 Page 28 of 56...

  • Page 29: Technical Details

    1.15 Technical Details. Tables 4a & b Burner Details No of Injectors Gas Connection ½ in BSP Internal thread Burner current 0.05 (per burner) Electrical Voltage/Ph/Hz 230 volt 1 phase 50Hz Burner type Burner details Gas category Heat input (Gross) 100% rate Nat Gas G20 Heat input (Gross) 50% rate Nat Gas G20 Gas consumption 100% rate Nat Gas G20 m³/h...
  • Page 30 Table 5. Heater Details Burner type Min distance between burners Max distance between burners 13.1 Min distance between burner and fitting Max tube temp °C Min mounting height Max burners per branch Table 6. Heater Noise Burner type db(A) Noise level @ 3m below In-Line BURNER NR±2 db(A)
  • Page 31 Table 8. Fan Details Fan type B160 B300 BH300 Fan part number 201760 201761 201762 201763 Motor (TEE) Q2E80M2D-KG-H Q2E90L2C-KG-H Q2E90L2D-KG-H Q2E112M2C-KG-H Power Supply to Fan V/Hz/P 230-50/3 230-50/3 230-50/3 415-50/3 Run Current 4.24 8.14 Start Current Speed 2850 2860 2840 2880 Wired...

  • Page 32: Commissioning Procedure

    Commissioning Commissioning Procedure Instructions. 3.3.1 Start Up Checks   These appliances should be commissioned by a 3.3.1.1 Check that the installation is to the design layout qualified engineer. drawing and installed in accordance with the installation   instructions. Tools Required.  ...
  • Page 33 Doc No. 700070 Page 33 of 56...
  • Page 34 The end vent vacuum is measured by removing the protection cap on the tee piece in the air impulse line on the end vent burner and connecting a manometer. 3.4.9 Press the jog dial to enter. Rotate jog dial until ‘HSP’ is displayed.
  • Page 35 Schneider Inverter Driven B80, B160, B300 Fan, Modulating Branch Damper (Zonal 3.4.19 Rotate jog dial until ‘HSP’ is displayed. Press jog dial to enter. modulation) 3.4.20 Rotate jog dial to adjust the frequency on the In this method, the fan is driven by the inverter and inverter until the high fire end vent suction is achieved adjusted to give the correct output for full fire.
  • Page 36 Menu selection Inverter Driven Modulating Fans (also save/OK ‘ ‘ and ( BH300 with ABB inverter) exit ‘ ‘) The use of an inverter allows the end vent suction to be adjusted by varying the output speed of the inverter within the local relay unit.
  • Page 37 4. Tighten grub screw (A) to secure damper position. FOLLOW INSTRUCTIONS ON P39 (3.8) FROM THIS POINT 3.6.16 Repeat procedure 3.6.14 for any further branches (where necessary), moving closer to the fan as each branch is completed. The vacuum setting procedure is now complete.
  • Page 38 Non-Inverter Driven Fans, Modulating Branch Damper (Zonal modulation) 3.8.1 Observe the ignition of ALL the burners. An amber (fans controlled by NRV ‘logic’ driven LRU’s with no inverter) neon should illuminate on the rear of the burner when the burner is lighting and remain if the burner has lit. If the End vent vacuum settings are made firstly by means of burner fails to light, the amber neon will extinguish adjusting the damper at the vacuum fan inlet, this brings...
  • Page 39 End vent vacuum settings are made firstly by means of adjusting the damper at the vacuum fan inlet, this brings 3.9.10 When the branch has been running for 30 minutes, the end vent with the lowest reading to the normal disconnect the 0-10V input to the dampers and check the operating vacuum.

  • Page 40: Final Commissioning

    3.10.6 Proceed to the next radiant branch closer to the fan 3.11.3 With all burners firing check the inlet gas pressure at and check the end vent vacuum reading. the burner furthest away from the gas supply. The min inlet pressure is 17.5mbar for G20 (Nat Gas), and 25mbar for G31 3.10.7 Adjust the branch damper (if necessary) located at (Propane).
  • Page 41 Doc No. 700070 Page 41 of 56...
  • Page 42 Doc No. 700070 Page 42 of 56...
  • Page 43 Doc No. 700070 Page 43 of 56...

  • Page 44: Servicing Instructions

    Servicing Instructions These appliances should be serviced annually by a competent person to ensure safe and efficient operation. In exceptional dusty or polluted conditions more frequent Various Pozidrive Various Flat Head Leather Faced servicing may be required. The manufacturer offers a Screwdrivers Screwdrivers Gloves...
  • Page 45 Figure 6.b. LR Burner breakdown - EV shown 1 Control housing base plate – L102001 2 Control housing lid – L102009 3 Full sequence gas controller – 2015 4 Multi functional gas valve – C111513 plus 900041 5 Air filter – L102013 26 Grommet (gas supply) –...
  • Page 46 4.3 Vacuum fan 4.8 Igniter assembly (11) Inspect fan and flue ductwork for any Check ceramic visually for build up of contamination. carbon or cracks. Inspect expansion joints for damage, Check the spark distance and position of the electrodes replace if necessary. relative to the burner head.

  • Page 47: Spare Parts

    Spare Parts. Note: Any spare part components that are not approved   by Nortek Global HVAC (UK) Limited could invalidate the 5.1 Required Spares approval of the appliance and validity of the warranty.   Only use Smartcom controllers with software version 3.1 or In order to aid troubleshooting and servicing, we higher.
  • Page 48 Item Description Part No. Item Description Part No. L100102- Burner Gasket (27)* L102032 Burner Head Assy (6) Ceramic Insert (7) L100155 Flame Retention (8) L100171 Mica Window (52) A523500 Sight Glass Cover (50) A571202 End Vent Window Gasket (51) C110350 Module Inverters: B80 Fan...
  • Page 49 5.2 NRV ‘M’ Injector/Air Shutter selection chart Jet (10) size Shutter (9) size EVM Orifice Plate Gas Type Burner dia mm / Part No. dia mm / Part no. dia mm / Part no. L100549 19.5 L100320 L104100 L100554 L100314 L104093 Natural Gas L100558...

  • Page 50: Fault Finding Guide

    Fault Finding Guide. Symptoms Possible causes Remedy Thermostat is satisfied. Check to see that thermostat is calling for heat. No power at burner. Check for 240V supply. Blown fuse in supply to heater. Check and replace if necessary. Vacuum fan is running Vacuum at end vent should be 6.25 mbar (2.5in but there is no power at End vent vacuum too low.

  • Page 51: Replacing Parts

    Replacing Parts. h: Lift burner clear of combustion chamber and withdraw. i: Remove the burner heat shield. j: When replacing do so in the reverse order ensuring that 7.1 Removal of burner the gasket between the burner heat shield and combustion assembly.
  • Page 52 f: Release three push clips (32) from controller fixing holes. h: Withdraw burner head and valve assembly from base plate. Retain burner gasket (28) for later. g: Remove controller (3) j: Secure burner head (6) and unscrew gas valve (4). h: Replace in reverse order.
  • Page 53 e: Disconnect electrical connections from the timer. f: Remove fixing screws from timer bracket and withdraw. 7.5 Pressure Switch (13) Replacement (EVM ONLY). a: Disconnect electrical supply. b: Release the slider latches (30) from the underside of the burner base plate. c: Pull lid (2) apart and upwards from base (1).

  • Page 54: Combustion Chamber

    g: Replace in reverse order. 7.8 Combustion Chamber Viewing Window Replacement. 7.7 Injector (10) Replacement. a: Turn off the system including the vacuum fan. (See figure 6a) a: Turn off gas and disconnect electrical supply. b: Release the slider latches (30) from the underside of the burner base plate (1).
  • Page 55 Notes Doc No. 700070 Page 55 of 56...

  • Page 56: Routine Maintenance Between Service Intervals

    Details are available on request. Contact the Nortek Global HVAC (UK) Limited Service department (details below). For Service requirements, please contact Nortek Global HVAC (UK) Limited (details below).

This manual is also suitable for:

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