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Installation , use and maintenance manual Gas fired radiant strips heating systems X CERK HE / X CERK HE-Jr pre-mix burner EVO4 Technoparc Saône Vallée Est- 215 Rue Marie Curie- 01390 Civrieux en Dombes Tel : 04 78 82 01 01 Fax : 04 78 82 01 02 www.exeltec.fr...
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WITH THE INSTALLATION AND USE OF THIS EQUIPMENT. KEEP THE MANUAL FOR FUTURE REFERENCE. This booklet has been prepared and printed by EXELTEC SAS. Reproduction, even in part, is forbidden without prior permission. Constant development in search of product improvement may lead, without advance notice, to changes or...
Contents INTRODUCTION ................. 3 WARNINGS ..................4 Special warnings ................. 5 Disposal .................... 5 2.2.1 Information to users ................5 General description ................6 Symbols and terminology used in the manual .......... 7 2.4.1 Terminology ..................7 2.4.2 Symbols ................... 8 INTENDED USE ..................
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5.9.5 Connection diagram for sensors and EU-CM300 user interface ....49 5.9.6 Electrical diagram for mod. HE ............51 5.9.7 Electrical diagram for mod. HE-Jr ............52 5.9.8 Electrical panel on board the machine (mod. HE / HE-Jr) ......54 5.9.9 EU-SP300 programmable power board ..........
INTRODUCTION This manual contains the description of X CERK HE EVO4 radiant strips heating system operation and the instructions necessary to correctly perform the main operations concerning installation, use and routine maintenance. The information provided is intended for a professional user. This user must have specific knowledge on the use of the heating unit, be properly instructed and trained and have the necessary authorization to operate on it.
2. Give this manual to the new owner and/or installer who will take care of the installation if the appliance is sold, or transferred. In case of loss, immediately ask EXELTEC for a copy; 3. EXELTEC disclaims any liability for direct or indirect damage to people, animals or objects arising from errors in installation, use, failure to comply with the instructions in this manual and in any case with the instructions provided by the manufacturer;...
2.1 Special warnings Check that the heat unit is pre-set to operate with the electrical power and the gas available in the network by checking what is indicated in the serial data on the unit. Check the seal of the gas supply installation, check that it has the suitable size for the necessary capacity and that it is equipped with all safety and control devices according to the laws in force.
The crossed bin symbol (Fig. 2.1) on the appliance or on its packaging indicates that the product, at the end of its operating life, must be collected separately and not disposed together with other mixed urban waste. Fig 2.1 Fig. 2.2 The separate collection of this equipment at the end of its life is organized and managed by the manufacturer.
2.4 Symbols and terminology used in the manual 2.4.1 Terminology DAMAGE Physical injury or damage to health Higher calorific value, it is the total quantity of heat emitted by a fuel mass unit dried till its intrinsic humidity, when this is subjected to complete combustion in presence of oxygen and when the products of combustion are back to the original pre- combustion temperatures;...
2.4.2 Symbols SYMBOL DESCRIPTION NOTE Indicates information useful for the correct operation of the system or behavioural indications. DANGER Indicates a high level of danger. Failure to comply may result in serious injuries or death DANGER Indicates a medium level of danger. Failure to comply may result in medium or serious injuries ATTENTION Indicates a warning.
X CERK HE/HE-Jr consists of aluminised steel fixed on the ceiling of the room to heat. The heated pipes emit infrared rays that heat the environment without creating air movement.
3.2 Identification data of the machine Each appliance is identified with a rating plate containing its technical characteristics and serial number. This label, together with warning ones, are applied on the electrical panel on board of the unit and they must not be removed. Below is an example of the aforementioned label.
4.1 Technical data in accordance with regulation (EU) 2015/1188 – DIRECTIVE 2009/125 / EC (ErP) Mandatory information for local space heaters for commercial use. XCERK-HE-Jr XCERK-HE-Jr XCERK-HE-Jr XCERK-HE-Jr Model identification: Heat generator to be installed outside the heated area Type of heating: radiant strips radiant strips radiant strips...
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Model identification: XCERK-HE 150 XCERK-HE 150 XCERK-HE 300 XCERK-HE 300 Heat generator to be installed outside the heated area Type of heating: radiant strips radiant strips radiant strips radiant strips Fuel Natural gas H Natural gas H Natural gas H Natural gas H Fuel Gaseous...
4.2 Dimensions of thermal units SX (left version) 1 = Gas connection Fig. 4.1 2 = Electrical connection Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 14...
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DIMENSION X CERK HE-Jr (mm) X CERK HE (mm) 1544 1757 1125 1023 WEIGHT 122 kg 190 kg Tab 4.4 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 15...
4.4 Radiant ducts dimensions in millimetres M12Ø3 model weighs 30 kg/m and has the following dimensions: Fig. 4.3 M8Ø3 model (on the left) weighs 25 kg/m while M4Ø3 model (on the right) weighs 19 kg/m. Their dimensions are: Fig. 4.4 M8Ø2 model (M8Ø2-RV with “V”...
4.5 Thermal unit components Fig. 4.6 POS. DESCRIPTION Delivery/return ducts Support for frame stirrups Access doors to burner/extractor (the model HE-Jr has one door only) Ø 150 mm female exhaust pipeline for HE and Ø 120 mm for HE-Jr Wall-crossing plenum Tab.
4.6 Radiant ducts components Fig. 4.7 POS. DESCRIPTION Suspension clamps Tubular frame Insulation with inorganic binder, covered with aluminium, positioned both sideways and above the radiant piping Emitting pipe suspension chain Emitting p i p e with high-temperature metallurgic treatment, done in controlled atmosphere for higher and more homogeneous emitting effect (female connection) Reflector for a better radiant efficiency (except for models M8Ø3 and M8Ø2-ST) Radiant ducts junction nipple (male connection)
INSTALLATION The installation must be performed by qualified personnel, in compliance with national and local regulations in force in the place of installation of the system. 5.1 Functional and surrounding spaces for the thermal unit When positioning the thermal unit, it is necessary to respect the distances shown in the following picture, which guarantee the correct supply of air to the burner and enough space around the unit for first ignition and maintenance operations.
Distance between radiant ducts and combustible material The radiant circuit must be installed respecting a minimum distance of 4 metres (trampling floor/ lower edge of the circuit). The distance between the external surface of the radiant ducts and any combustible materials stored must be such as to prevent dangerous temperatures from being reached on the surface of the materials themselves, which would possibly cause fires and/or combustion reactions, and in any case not less than 1.5 metres.
Avoid contact with elements that could damage the system components (e.g. sharp, pointed elements etc.). EXELTEC disclaims any liability for damage caused by incorrect operations, by unqualified personnel, by the use of improper means or by lack of protection from atmospheric agents.
5.3.1 Handling the thermal unit using eye-bolts (only mod. HE) The fixing screws of handling eye-bolts are on the upper part of the thermal unit, under the top cover. To find them, remove the top cover as shown in Fig. 5.4. Fig.
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Pay attention in handling the unit with eye-bolts, as the thermal unit could get an inclination backwards to balance its weight. The position of the suspension points is not the same of those of the barycentre of the thermal unit (Fig. 5.5). Fig.
The structural engineer must verify whether the wall is able to support the thermal unit and define as well the way of anchoring. The holes necessary to fix the frame of the X CERK HE-Jr combustion chamber must be done using a template with the same dimensions indicated in Fig. 5.6.
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The holes necessary to fix the frame of the X CERK HE SX (left version) combustion chamber must be done using a template with the same dimensions indicated in Fig. 5.7. Fig. 5.7 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN...
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The holes necessary to fix the frame of the X CERK HE DX (right version) combustion chamber must be done using a template with the same dimensions indicated in Fig. 5.8 Fig. 5.8 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN...
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Once the holes are done, proceed to fix the frame as shown indicatively in Fig. 5.9. Fig. 5.9 POS. DESCRIPTION Reinforcing profile (mod. HE-Jr features two horizontal reinforc i ng prof il es) Screwed bar Washer Frame EI 120 panel Tab.
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Fig. 5.10 POS. DESCRIPTION Closing frame for EI 120 panel EI 120 panel Thermal unit Thermal unit supporting frame T ab. 5.2 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 30...
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At this point, place the unit on the frame, sliding it as shown below: Fig. 5.11 Fig. 5.12 Seal the lateral and upper edges of the thermal unit to avoid any possible infiltration through the wall hole. Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 31...
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Fig. 5.13 Block the unit to the frame with no.6 - 4.8x32 mm screws for HE models and no.4 4.8x32 mm screws for HE- Jr models (screws are standard supplied). Fig. 5.14 Insert the closing frame by cutting the corners at 45° and fix them to the wall with screws and dowels.
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Fig. 5.15 Fig. 5.16 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 33...
5.5 Installation of the thermal unit over roof Fig. 5.17 Fig. 5.18 POS. DESCRIPTION Closing plate Lower protection with insulation Inlet hole Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 34...
5.6 EXHAUST PIPE Respect the maximum length of 8 metres (mod. HE) and 5 metres (mod. HE-JR) (*). All the accessories for flue pipes (available on demand) are approved as required by the current European norm. (*) Consider that each 90° curve corresponds to 1.5 linear metres of duct. Appliance type B This typology includes the fumes exhaust outside the building, with connection to chimney or flue system through a proper duct realized with certified components...
In this regard, if it is not possible to guarantee the absence of such infiltrations from the joints or from the expulsion terminal, EXELTEC recommends providing an appropriate system for conveying the infiltration water starting from the discharge point.
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Fig. 5.20 The second module of the radiant circuit is characterised by the presence of an expansion joint on one of the two pipes (the one affected by the higher temperatures, it corresponds to the branch of the combustion chamber). With respect to an observer standing underneath the radiant modules with the thermal unit behind them, the expansion joint must necessarily be in the pipework where the combustion chamber is located (flue gas outlet side), as shown in the following picture, which shows both right and left side models, seen from above (Fig.
For the coupling first-second modules, see the indications in the next paragraphs. 5.7.2 Installation of the next modules Couple the pipes of the modules according to the layout elaborated by EXELTEC technical dept., paying special attention on the position of the modules with thermal dilation joints (see par. 5.7.3 Couple the pipes of the modules distributing sealant in the two dedicated recesses on the outer perimeter of the nipple as shown in Fig.
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Fig. 5.22 Include No.4 8x25 mm screws and nuts for the junction of the frames between modules (Fig. 5.23 - not supplied by EXELTEC). Connect the frames of consecutive modules. Fig. 5.23 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 39...
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Each pipe/nipple coupling, not considering the initial one between start module and combustion unit, must be blocked with self-drilling screws (No.3 screws for each pipe- not supplied by EXELTEC) positioned on the pipe suspension clamps as indicated in Fig. 5.26. Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN...
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Fig. 5.26 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 41...
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To suspend radiant ducts on the ceiling, use a suitable chain (specific weight of modules: 30 kg/m per mod. M12Ø3, 25 kg/m per mod. M8Ø3 and 20 kg/m per mod. M8Ø2) to be attached to support brackets positioned 3.0 to 4.5 m apart (Fig. 5.27). The chain eye must have a size adequate for the use with M8 screws.
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Stirrups must be hooked to the frame of the module as indicated in the detail of Fig. 5.27 Include a screw coupling for the regulation of the chain. Fig. 5.28 Use an M8 shackle or nut (min.) for the stirrup/screw coupling and screw coupling/chain fixing. Once the circuit is completed, check that the modules are horizontally levelled, adjusting the screw couplings (Fig.
5.7.3 Expansion joints To compensate the thermal dilations arising along the pipeline, some modules are equipped with expansion joints. The modules with joint must be positioned in the circuit according to the installation scheme supplied with the system. During installation it is necessary to check that the joints are completely extended and not compressed, so as to guarantee the absorption of the expansions during the normal operation of the system.
The diagram in Fig. 5.31 shows the components that characterise the gas ramp recommended by EXELTEC and is just an example. The design of the gas distribution network and its components remains the responsibility of the designer in charge, who will take into consideration the conditions prescribed in this manual for the fuel gas supply.
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Fig. 5.31 POS. DESCRIPTION Expansion joint Pipe for quantometer mounting (L=200÷250 mm) [*] Possible reduction group Filter Pressure tap Ball valve [*] To be used only when the system is not equipped with its own gas contactor. Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 46...
5.9 Electrical connections Electrical connections must be realized by qualified personnel, adequately skilled, in compliance with national and local regulations in force in the country of installation. Connect the external power supply to the terminals positioned in the on board electrical panel (see Fig.
5.9.4 Connection terminal board Fig. 5.32 POS. DESCRIPTION Ignition actuator (damper or solenoid valve) Ignition transformer Remote Reset Contact Flame signal (FL) and Lockout signal (LO) F2 Fuse 1A type F – EU-SP300 card protection F1 Fuse 6.3A type F – Service outlet protection Universal service outlet –...
5.9.5 Connection diagram for sensors and EU-CM300 user interface Fig. 5.33 Legend SI-1 = Primary internal sensor SI-2 = Secondary internal sensor SE = External sensor CM = EU-SP300 user interface SP = EU-SP300 control board Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 49...
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For correct operation, each thermal unit requires the presence of a probe detecting the radiant temperature of the system (SI-1 - Primary globothermometric probe); under normal operating conditions, the monitoring of this value permits to go as close as possible to the set-point. The principal globothermometric probe - EU-RT020 - is equipped with a key switcher, permitting to force the operation of the unit by bypassing the programmed time schedule;...
5.9.7 Electrical diagram for mod. HE-Jr Fig. 5.35 Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 52...
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Below is the legend of the wiring diagrams in Fig. 5.34 and Fig. 5.35. REF. DESCRIPTION Ignition transformer EU-CM300 user interface 230 Vac universal service outlet Ignition/ionisation electrode Solenoid valve 6.3 A quick blow fuse (F) socket protection 1 A quick blow fuse (F) EU-SP300 card protection Manual main circuit breaker with door lock Recirculation fan fitted with inverter Recirculation pressure switch 0.2÷3 mbar...
5.9.8 Electrical panel on board the machine (mod. HE / HE-Jr) Fig. 5.36 For the programming of the EU-SP300 power board through EU-CM300 user interface, refer to the technical instruction IT_EU-SP300. REF. DESCRIPTION Flame control and modulation card T-type 10 A fuse main circuit breaker Manual main circuit breaker with door lock EU-SP300 burner control board 230 Vac universal service outlet...
The EU-SP300 power board, installed in the unit, is programmable. Programming is normally carried out in the company. Any updates can be made via the iFS key containing the update files owned by EXELTEC or remotely, if the system is within an EUBus network with a centralised EU-Qbo300 interface.
5.9.11 EUBus network connection scheme for EU-NET and EU-VISION configurations Two internal temperature probes (one primary and one secondary with the possibility to perform a weighted average), an external probe and an EU-CM300 user interface can be connected simultaneously to an EU-SP300 control board. In case of an EUBus network, as in this example, only one external probe is required for the entire network (consisting of a maximum of 16 units from 0 ÷...
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RS-485 cable poles twisted and shielded cable Câble blindé Centralised Interface Qbo300/ Qbo100 Fig. 5.37: Example of an EUBus network configuration. Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 57...
WORKING SEQUENCE Fig. 6.1 REF. DESCRIPTION Room temperature Current setpoint Sp-rd Re-ignition .t.T Sp-LPb Modulation band Recirculation fan Mvmax Recirculation fan maximum speed Mvmin Recirculation fan minimum speed Burner fan VBPmax Burner fan maximum speed VBPmin Burner fan minimum speed Gas solenoid valve status Igniter status Ignition actuator status...
COMMISSIONING, SERVICE AND MAINTENANCE 7.1 Safety requirements The personnel in charge of the maintenance of the unit, the radiant modules and all the elements connected to them, apart from being professionally qualified, must not wear clothing that could cause danger (wide sleeves, laces, belts or similar) and must use personal protective equipment in compliance with the laws in force.
In consideration of the fact that, in most cases, they are placed on the wall at significant heights, EXELTEC strongly recommends the installation of a permanent system to have access the units, complete of the relative work platform. It is possible to order a modular system which can be configured quickly and easily.
7.4 Ordinary maintenance – General indications and prescriptions The X CERK HE radiant strips heating system must be subjected to routine maintenance in accordance with the regulations in force, the rules of good practice and as indicated below.
Ordinary maintenance operations generally consist in cleaning the main components of the unit, as well as checking their functionality. Regardless of any legal restrictions and requirements, EXELTEC recommends carrying out the smoke analysis at the completion of the maintenance operations and after the operating configuration of the unit has been restored.
In the case the system is installed in environments where it is impossible to avoid a significant formation of dusty deposits, EXELTEC suggests the installation of the upper metal covers. Their smooth shape make the cleaning extremely easy.
Please contact an authorised service possible combustion unit and, centre, IT_EU_PY_02 replacement oxidated/damaged, replace them. EXELTEC suggests their annual replacement. Solenoid valves Verify with the special device Please contact an authorised service upstream pressures that the intake pressures of the...
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Activity Description Paragraph/ref. figure Vacuum control Using differential pressure Please contact authorised service gauge, check that the minimum centre, IT_EU_PY_01 vacuum values of the system are guaranteed. Ignition cycle control Visual check ignition Chapter 6, page 63 sequence and search for any anomalies/controller display signalling.
TROUBLESHOOTING The EU-CM300 user interface recognises and displays the single working status of the thermal unit, included the burner and recirculation fan malfunctions. The ALSt menu of EU-CM300 user interface permits the reading of errors which are already occurred, active or solved (see the IT_EU-SP300 technical instructions to navigate the menu). 8.1 Error code identification When icon...
8.2 Error removal procedure The following tables show the error codes divided as follows: Error codes relating to the whole unit, communicated by the EU-SP300 power board and visible in the ALSt menu; Error codes relating to the burner, communicated by the flame control board and available in parameter U02 of the inFo menu;...
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ALSt ERRORS TABLE Error Code Reason Elimination No probe is present or in short circuit, check the wire and the connection; faulty probe, to be replaced; Fumes temperature temperature beyond the limits of the instrument, check the fumes A 22 probe error P3 temperature;...
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ALSt ERRORS TABLE Error Code Reason Elimination check that the probe is correctly connected to terminal J2 of the EU-SP300 board; check the integrity of the connection wires of the P3 fumes probe, replace the probe if necessary; ...
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U02 BURNER ERRORS TABLE Error Reason Elimination Code Check the ignition and ionisation electrodes and the relating wiring, if necessary clean/replace them; check the ignition transformer and the power supply wire, replace them if necessary; check the opening of the gas solenoid valve and the supply cable, replace them if necessary;...
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U02 BURNER ERRORS TABLE Error Reason Elimination Code Speed fan > 0 when U01 = 06, after a timeout of 30s, check the fan burner, the PWM data wire and the supply wire, Lockout caused by missed replace them if necessary; fan burner shutdown ...
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U02 BURNER ERRORS TABLE Error Reason Elimination Code Lockout caused See error code 51; malfunction check the direction of rotation of the recirculation fan, if it pressure switch during turns in the opposite direction, reverse a motor power supply start-up from the inverter.
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Y01 INVERTER ERRORS TABLE Error Reason Elimination Code It occurs when the temperature of the power module exceeds 80°C, check that the working environment of the inverter is free and clean Power module over and that natural ventilation is ensured; temperature error ...
8.2.1 Errors reset Reset the error by bringing the rSt parameter (from Fnc menu) to YES The error is unlocked Damages caused improper fault reset Improper fault reset can lead to material damage or serious injury. Do not perform more than 2 consecutive resets; ...
8.3 Problems during operation In this paragraph are shown any problems that may arise during the normal operation of the thermal unit. TABLE OF PROBLEMS DURING OPERATION Observation Reason Elimination Incorrect start-up point Perform the calibration according to the technical calibration instructions IT_EU_PY_01.
8.4 Operation status and burner cycle diagram In this paragraph are shown in detail the working status of the burner, also illustrates by means of the cycle diagram. The operation status of the burner is indicated on parameter U02 of inFo menu of the EU-CM300 interface.
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BURNER CYCLE DIAGRAM LEGEND Initial Meaning Temperature request, via ModBus (from EU-SP300 power board) Safety termostat Air pressure switch Burner fan RPM BF Burner fan modulation point Ignition transformer Gas solenoid valve Ionization signal Flame signalling Block signalling T P1 Pre-ventilation time 1 equal to 45 seconds T P2 Pre-ventilation time 2 equal to 15 seconds...
For each thermal unit, at the time of commissioning, a specific Commissioning Form (mod. M8.3- 02) must be filled in as a test report according to UNI 10389-1. The guarantee is valid only if a copy of this document is sent to EXELTEC within 7 working days of issue.
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even slight tampering with the product or parts of it and / or changes in settings / calibrations, unless previously agreed and validated by EXELTEC; use of fuel other than the type for which the thermal unit has been set up and calibrated;...
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Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 80...
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Technoparc Saône Vallée Est 215 Rue Marie Curie 01 390 CIVRIEUX EN DOMBES Tel. 00 33 (0)4 78 82 01 01 Fax. 00 33 (0)4 78 82 01 02 Mail : info@exeltec.fr www.exeltec.fr Installation manual X-CERK HE EVO 4 -2022-11--Iss1-0-EN Page | 81...
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