Schwank infraSchwank D Series Technical Manual
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Schwank infraSchwank D Series Technical Manual

Radiant tube heater
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infraSchwank D / calorSchwank D
Radiant Tube Heater
15 U / 20 U / 30 U / 40 U / 50 U / 60 U
1-stage / modulating lambdaPlus
single heater and flue gas collection system [herringbone] type F
Technical Manual
Technical Instructions
Operating Instructions
Legal Requirements
Assembly Instructions
Installation Instructions
0085BO0037
Commissioning
Service Guide

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Summary of Contents for Schwank infraSchwank D Series

  • Page 1 infraSchwank D / calorSchwank D Radiant Tube Heater 15 U / 20 U / 30 U / 40 U / 50 U / 60 U 1-stage / modulating lambdaPlus single heater and flue gas collection system [herringbone] type F Technical Manual Technical Instructions Operating Instructions Legal Requirements...
  • Page 2 Internet: www.schwank.de Schwank companies in: Austria ▪ Belgium ▪ Canada ▪ China ▪ Czech Republic ▪ France ▪ Germany ▪ Great Britain ▪ Hungary ▪ Netherlands ▪ Poland ▪ Romania ▪ Russia ▪ Slovakia ▪ Ukraine ▪ USA ▪ Distribution in more...

  • Page 3: Table Of Contents

    Content Introduction ................................4 Your Safety ................................4 Notes for your safety ..........................4 Scope of Delivery ............................... 5 Planning ................................7 Position of suspension ..........................7 Positioning ..............................8 Air supply / Exhaust Requirements ......................9 Legal Requirements ............................17 Operation ................................

  • Page 4: Introduction

     maintenance / trouble shooting space heating. Any other use is not permitted and therefore Schwank is not liable for any improper You need an explicit permission from the use. manufacturer for any kind of changes and reconstruction.

  • Page 5: Scope Of Delivery

    infraSchwank D / calorSchwank D shape U 3 Scope of Delivery reflector long reflector short tube bar burner kit suspension bracket radiant tube flange packing turnaround box turbulator Fig. 1: Tube heater infraSchwank D / calorSchwank D 20U Scope of delivery Accessories The radiant tube infraSchwank D / calorSchwank D ...
  • Page 6 infraSchwank D / calorSchwank D shape U Structure of burner kit Fig. 2: Burner kit with burner control unit IC 4000/1 1. Burner control unit IC4000/1 15. Ignition cable 2. Air pressure switch 16. Ionisation cable 3. Fan air restrictor plate 17.

  • Page 7: Planning

    infraSchwank D / calorSchwank D shape U 4 Planning Distances to flammable materials in the radiant area Room temperature control Radiant tubes must be positioned so that the surface temperature of: Radiant tube heating-systems must be equipped with a temperature control. ...

  • Page 8: Positioning

    Avoid therefore inflexible suspension. Do not use fixing elements like open hooks etc. SCHWANK GmbH will not accept liability Hang the heater in balance. We recommend the for damages caused by incorrect use of turnbuckles or adjustable steel cable grips mounting of the burner unit.

  • Page 9: Air Supply / Exhaust Requirements

     For exact dimensioning and positioning of supply air and exhaust air outlet of the building according to EN 13410 or G 638-2 please contact Schwank GmbH, phone +49 [0] 221 / 7176 0.
  • Page 10 3. Exhaust flue with individual exhaust system - construction and layout of such installations must combustion air from outside the room be carried out by Schwank employees, as well as [Type C] commissioning. The strict observance of the Combustion air and exhaust air are to be...
  • Page 11 infraSchwank D / calorSchwank D shape U Flexible exhaust system infraSchwank D / calorSchwank D 15-40U [wall terminal] - version aluminium - The stainless flexible pipe [exhaust Please note the safety distance to line] must be installed uncut for the flammable materials: heater 40/50/60U.
  • Page 12 infraSchwank D / calorSchwank D shape U Flexible exhaust system infraSchwank D / calorSchwank D 15-60U [roof terminal] - verison aluminium - The stainless flexible pipe [exhaust line] Please note the safety distance to must be installed uncut. Make sure that flammable materials: there is no sink in the pipe.
  • Page 13 infraSchwank D / calorSchwank D shape U Flexible exhaust system deltaSchwank [wall terminal] infraSchwank D / calorSchwank D 15-60U - version stainless steel - Please note the safety distance to Install stainless steel flexible pipe flammable materials: without sink. - single-wall exhaust pipe: 80 mm Join parts of the roof terminal strongly - double-wall exhaust pipe together by compression and using...
  • Page 14 infraSchwank D / calorSchwank D shape U Flexible exhaust system [roof terminal] infraSchwank D / calorSchwank D 15- 60U - version stainless steel - Please note the safety distance to Install stainless steel flexible pipe flammable materials: without sink. - single-wall exhaust pipe: 80 mm Join parts of the roof terminal strongly - double-wall exhaust pipe together by compression and using...
  • Page 15 infraSchwank D / calorSchwank D shape U Exhaust system deltaSchwank [roof terminal] with downstream heat exchanger tetraSchwank in room air operation and with outside air intake in fresh air operation - version stainless steel - Please note the safety distance to Install stainless steel flexible pipe flammable materials: without sink.
  • Page 16  Tube heater infraSchwank D/ calorSchwank D must only be done by Schwank.  Spiral duct and connection elements for Planning details have to be strictly exhaust collecting system [different...

  • Page 17: Legal Requirements

    infraSchwank D / calorSchwank D shape U 5 Legal Requirements In Germany the following rules, standards and We recommend that these installation guidelines regulations must be observed. should be observed with the relevant Building Standards Regulations of your country. Comply EnEV Verordnung über with any local by-laws and the current IEE Wiring...

  • Page 18: Operation

    Servicing should be carried out not less than once a year by a qualified service engineer. After any servicing, the heater SCHWANK will not accept liability damages must be recommissioned as detailed in caused by improper assembly and/ or operating Chapter 12.

  • Page 19: Technical Specification

    infraSchwank D / calorSchwank D shape U 7 Technical Electrical connection power supply Single-phase AC 230 V, N, PE - 50Hz specification The connecting cable for the power supply is connected to the IC 4000/1 burner control with Appliance Automatic heating device, heat the provided 4-pin plug.
  • Page 20 infraSchwank D / calorSchwank D shape U infraSchwank D / calorSchwank D 30U infraSchwank D/ calorSchwank D 40U infraSchwank D / calorSchwank D 50U infraSchwank D / calorSchwank D 60U Fig. 16: Measurements infraSchwank D / calorSchwank D 30U, 40U, 50U and 60U [view from below]...

  • Page 21: Technical Data

    infraSchwank D / calorSchwank D shape U Technical data for single and modulating operation lambdaPlus infraSchwank D / calorSchwank D 15 U 20 U 30 U 40 U 50 U 60 U Nominal heat load [kW] 15,0 19,0 29,0 39,0 49,0 60,0 Nat.
  • Page 22 infraSchwank D / calorSchwank D shape U infraSchwank D / calorSchwank D 15 U 20 U 30 U 40 U 50 U 60 U Nat. Gas H Gas nozzle Ø 3,50 Ø 3,85 Ø 5,00 Ø 5,85 Ø 6,90 Ø 6,90 D 50+IA* G 20 Fan air restrictor plate...

  • Page 23: Operating Description

    infraSchwank D / calorSchwank D shape U 8 Operating description Fault Start-up If no flame is reported during the pre-purge period If heat demand exists, the fan will start up [including 1 repetition of ignition process], the automatically. A differential pressure arises in the burner control unit IC 4000/1 will switch off the burner box, which is reported to the ignition unit via radiant tube, error will give, fan runs in post-purge...

  • Page 24: Assembly Instructions

    infraSchwank D / calorSchwank D shape U 9 Assembly instructions Assembly radiant and burner kit Assembly infraSchwank D / calorSchwank D 15U Tools you need   Flue gas connection [Type B23, C] • hexagonal wrench or ratchet Flexible stainless steel pipe with connector [width: 10, 13] flange has to be mounted at the end of the •...
  • Page 25 infraSchwank D / calorSchwank D shape U Assembly infraSchwank D / calorSchwank D 20U  Tools you need • hexagonal wrench or ratchet [width: 10, 13] • socket wrench [width: 7 and 8] Note before mounting  Flue gas connection [type B23, C] ...
  • Page 26 infraSchwank D / calorSchwank D shape U Assembly infraSchwank D / calorSchwank D 30U  Tools you need • hexagonal wrench or ratchet [width: 10, 13] • socket wrench [width: 7 and 8] hand rivet tool, drill machine,  drill  4.9 mm Note before mounting ...
  • Page 27 infraSchwank D / calorSchwank D shape U Assembly infraSchwank D / calorSchwank D 40U  Tools you need • hexagonal wrench or ratchet [width: 10, 13] • socket wrench [width: 7 and 8] Note before mounting  Note the distance measures of suspension brackets.
  • Page 28 infraSchwank D / calorSchwank D shape U Assembly infraSchwank D / calorSchwank D 50U  Tools you need • hexagonal wrench or ratchet [width: 10, 13, 17] • socket wrench [width: 7 and 8] Note before mounting  Note the distance measures of suspension brackets.
  • Page 29 infraSchwank D / calorSchwank D shape U Assembly  Accessory for indirect flue into the room [Type A] infraSchwank D / calorSchwank D 60U Flue gas diverter code-no. 126 7018 0 or flue gas adapter code-no. 126 7035 0 Tools you need ...

  • Page 30: Assembly Burner Kit Exhaust Gas Collection System

    infraSchwank D / calorSchwank D shape U Assembly burner kit exhaust gas collection system Conversion kit burner kit single heater to exhaust gas collection system Article No. 126999 9 Conversion kit includes the components for converting the burner kit for use in an exhaust gas collection system and provides the parts for Fig.
  • Page 31 infraSchwank D / calorSchwank D shape U Fig. 27: View burner kit after conversion Fig. 28: Assembly connection parts exhaust gas...

  • Page 32: Installation Instructions

    10 Installation Please consider the pressure drop of the upstream instructions mounted gas connection and gas filter. For the detailed pressure drop value of the Schwank gas- pipe-systems see table 7. Danger of fire and explosion! Unprofessional handling of gas pipes,...
  • Page 33 infraSchwank D / calorSchwank D shape U Note the following points while installing the gas-pipe-system:  Use only gas lines as per national standards.  Never hang heaters on the gas pipes.  Mount a manual gas cock upstream of every radiant tube.

  • Page 34: Exhaust Flue Installation Single Heater

    When starting the central exhaust fan for the first time all tube connections have to be checked for tightness.  If the Schwank planning requires a condensate run off, this part must be mounted directly in front of the exhaust fan [deepest point of the system].

  • Page 35: Electrical Installation [Wiring Diagram]

    infraSchwank D / calorSchwank D shape U Electrical installation Modulating operation [wiring diagram] lambdaPlus  In the standard case 230 VAC error signal is Danger of electric shock! given via contact 3 at 4-pin plug. Electric shocks are highly dangerous! Working at the electrical equipment of For modulating operation without MODBUS ...

  • Page 36: Electrical Connection Operation With Modbus Control

    infraSchwank D / calorSchwank D shape U Electrical connection Electrical connection exhaust gas collecting system Operation with MODBUS control [herringbone system] After conversion of the heaters to operation with  Route a flexible 3-wire electrical connection exhaust gas collection system they can be cable [max.
  • Page 37 infraSchwank D / calorSchwank D shape U Fig. 35: Wiring scheme burner kit infraSchwank D / calorSchwank D with MODBUS control to SchwankControl Touch...
  • Page 38 infraSchwank D / calorSchwank D shape U Fig. 36: Wiring scheme burner kit infraSchwank D / calorSchwank D 1-stage via relay control SchwankControl Touch - without MODBUS control...
  • Page 39 infraSchwank D / calorSchwank D shape U Fig. 37: Wiring scheme burner kit infraSchwank D / calorSchwank D modulating via relay control SchwankControl Touch - without MODBUS control...
  • Page 40 infraSchwank D / calorSchwank D shape U Fig. 38: Wiring scheme burner kit infraSchwank D / calorSchwank D exhaust gas collecting system with SchwankControl Touch / extension kit Fan Control SAV1...
  • Page 41 infraSchwank D / calorSchwank D shape U Fig. 39: Wiring scheme burner kit infraSchwank D / calorSchwank D 1-stage with alternative control unit SRT-1 Fig. 40: Wiring diagram burner kit 1-stage Fig. 41: Wiring diagram burner kit modulating infaSchwank D / calorSchwank D infraSchwank D / calorSchwank D...

  • Page 42: Commissioning Instructions

    infraSchwank D / calorSchwank D shape U Commissioning instructions Before commissioning A qualified service engineer must carry out this operation. The correct operation and fixing of the heater is prerequisite for the warranty. Checking gas lines and flue system is not included in this service.

  • Page 43: Parameter Ic 4000/1 And Setting

    Parameter IC 4000/1 and setting The burner control unit IC 4000/1 is already factory preset. The parameters can be read out by the Schwank Service Software IC 4000 [RS-485 interface board] and if necessary to be changed. Parameter selection and settings can made manually direct at IC 4000/1 by the two push buttons SW 2 and SW 3 and the 7-segment display.

  • Page 44: Assignment Modbus Address

    infraSchwank D / calorSchwank D shape U Fig 42: 7-segment display and push buttons IC 4000/1 ON normal working mode DISP1 is blank. When you need to enter parameter setting: - Press SW2 and SW3 buttons together for 3 seconds. - Parameter number “1”...

  • Page 45: Adjusting Nominal Thermal Load At Single-Stage Operation

    infraSchwank D / calorSchwank D shape U Adjusting nominal thermal load at Adjusting thermal loads single-stage operation for modulating operation lambdaPlus Attention! The pressure control unit is pre-adjusted It is necessary in addition to the mechanical on natural gas / propane. Do not put the factory setting of the modulating gas pressure to appliance into operation uncontrolled.
  • Page 46 infraSchwank D / calorSchwank D shape U Now press buttons SW3 [-] oder SW2 [+] so that the measured nozzle pressure will be 1 mbar above the required maximum value [e.g. 13 hPa]. 15. If the value cannot be reached, the maximal mechanical limitation at the modulating regulator [large adjusting screw C] needs to be amended.
  • Page 47 infraSchwank D / calorSchwank D shape U Fig. 46: Board IC4000/1 with 7-segment display and push buttons SW 2 / SW 3 Dia. 1: Fan voltage phase angle control drive vs. value PP03...

  • Page 48: Commissioning Exhaust Gas Collecting System [Herringbone]

    For first start up and commissioning of the system please request a Schwank service engineer to Required negative pressure level at test nipple attend Adjustment by Schwank is a condition of nozzle pressure [cold conditions]: our warranty. - infra/calorSchwank D 15-60U: -0,8…-1,5 hPa...

  • Page 49: Determination Of Nozzle Pressure

    infraSchwank D / calorSchwank D shape U Determination of nozzle pressure Example for the determination of the nozzle pressure Diagram 2: Wobbe-Index profile Natural gas infraSchwank D / calorSchwank D 15 – 50U Diagram 3: Wobbe-Index profile Natural gas infraSchwank D / calorSchwank D 60U...

  • Page 50: Service Guide / Trouble Shooting

    infraSchwank D / calorSchwank D shape U 12 Service guide / Trouble shooting Maintenance and annual check A regular maintenance is the requirement for a Any deviations must be fixed immediately. Defect faultless operation of the appliance. parts must be changed directly. According to the National Standard Regulations, Maintenance work on gas valves, flame sensing heating-systems with radiant tubes must be...

  • Page 51: Error Codes

    infraSchwank D / calorSchwank D shape U Error codes Error in gas valve Gas valve drive or feedback feedback error If an error occurs, all gas valves are closed and the check circuitry lockout message output [230V] is activated and Ionization Ionization signal is the error code is stored internally and transmitted...

  • Page 52: Troubleshooting / Error Causes

    infraSchwank D / calorSchwank D shape U Troubleshooting / Error causes Error code 1: - no gas [e.g. gas line not vented, gas cock closed] - faulty gas valve - Ignition and ionization electrodes damaged / dirty - wrong setting gas throttling screw - poor grounding Error code 2: - poor low ionization current [<0,7A DC]...

  • Page 53: Change Of Gas Family

    infraSchwank D / calorSchwank D shape U 13 Change of gas family Fig. 47: Change of gas family  Burner baffle [only 15 / 20 / 30 / 40U]  Burner cup  Burner nozzle  Air baffle plate [only 15 / 20 / 30 / 40U] ...

  • Page 54: Accessories

    infraSchwank D / calorSchwank D shape U 14 Accessories Ball guards Ball protection grids acc.18032-3 for using heaters in sport halls [grid 40x40mm]. Delivery scope Mounting set complete for each type of heater existing of: infra/calorSchwank D shape U Ball protection grid L=1443mm Ball protection grid L=1843mm Ball protection grid L=2203mm Ball protection grid L=2963mm...
  • Page 55 infraSchwank D / calorSchwank D shape U bracket for further assembling next protection grid. Put next segment ball protection grid L= 1843mm from below on angle brackets and mount clamps with self-locking nuts M8 Last segment ball protection grid L= 1843mm protects the burner unit at the bottom.
  • Page 56 infraSchwank D / calorSchwank D Form U Fig. 50: Fixed end bracket on turnaround box Fig. 53: Loose mounted clamp Cut out on fan side Fig. 54: Cut out on fan side for mounting and compensation thermal length expansion - only 50/60kW Fig.

  • Page 57: Reflector Elongation

    infraSchwank D / calorSchwank D shape U Reflector elongation Vertical elongation of reflectors b=415mm for thermal protection. The numbers of reflector elongation [single sheets] is depending on required protection [one side both side, protection length] and the power of the radiant heater. Delivery scope The required reflector elongation can be compiled depending on the extent of necessary...

  • Page 58: Set Angled Mounting Tubes

    infraSchwank D / calorSchwank D shape U Set angled mounting tubes Gas filter groups Bracket to ensure form and position of reflectors To avoid technical problems with the gas when the heater is mounted angled [>15°]. combination valves which are caused by Mount bracket to at each junction point pollution of dust or rust coming out of the gas pipe reflector/reflector, not at reflector end caps.

  • Page 59: Water Protection Box Burner Kit

    infraSchwank D / calorSchwank D shape U Water protection cover burner kit Protection cover of the burner kit 15-60U with protection class IP 55 against water or aggressive mediums, cover complete in stainless steel. In delivery scope a mounting set existing of: ...

  • Page 60: Tetraschwank

     Condensate pipes must be installed with a slope to the discharge into the sewer system.  Connect the ventilator as shown in Fig. 41 to the central control unit Schwank Control Touch. Electrical connection ventilator Fig. 65: Electrical connection tetraSchwank to SchwankControl Touch...

  • Page 61: Spare Parts

    infraSchwank D / calorSchwank D shape U 15 Spare parts 12 13  10 11    Fig. 66: Spare parts infra D / calor D 20U Pos. Part Art.-No. Burner kit infra D / calor D 15U Natural Gas H 126 9211 1 Burner kit infra D / calor D 20U Natural Gas H 126 9221 1...

  • Page 62: Spare Parts Infraschwank D / Calorschwank D 15-60U

    infraSchwank D / calorSchwank D shape U Spare parts infraSchwank D / calorSchwank D 15-60U Fig. 67: Spare parts burner kit Spare parts burner kit infra D / calor D 15-60U Pos. Part Art.-No. Spark igniter with ionisation cable 127 0246 9 Ignition wiring with plug 126 7021 5 Spare part burner control unit IC 4000/1 for infraSchwank D / calorSchwank D...

  • Page 63: Ec Type Examination Certificate

    infraSchwank D / calorSchwank D shape U 16 EC type examination certificate...
  • Page 64 infraSchwank D / calorSchwank D shape U...

  • Page 65: Ec Declaration Of Conformity

    infraSchwank D / calorSchwank D shape U 17 EC declaration of conformity...

  • Page 66: Product Information Related To Ecodesign Regulation No 2015/1188

    infraSchwank D / calorSchwank D shape U 18 Product information related to Ecodesign Regulation No 2015/1188 infraSchwank D Values 15/1 U 15/M+ U 20/1 U 20/M+ U 30/1 U 30/M+ U 40/1 U 40/M+ U 50/1 U 50/M+ U 60/1 U 60/M+ U Nominal heat input [kW] @ NCV 15,0 15,0...

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