Download Service manual Gryp 2006 GB - Energlo Diesel Heaters Inc.
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SPACE HEATERS WITH COMPRESSOR MAINTENANCE AND SERVICE MANUAL 1 THE MAINTENANCE OPERATIONS DESCRIBED IN THIS MANUAL MUST ONLY BE CARRIED OUT BY QUALIFIED TECHNICIANS RESPECTING ALL SAFETY RULES USE ONLY ORIGINAL SPARE PARTS RECOMMENDED BY THE MANUFACTURER 2 INDEX ! " # ! $ % $ $ $ $ $# $$ $* $+ $, $ / $ $ $ $ $ # $ $ $ * $ + $ , $ / $ * 4 + 5 " " " " () " " " " " & & & & " " " " " & & & & & " " " 1 & & & ' & & & & & .. 0 0 - 0 2 3 3 1. FUNCTIONING SCHEME OF DIRECT FIRED HEATERS D % " " 6 7 ! ( 8 1 9 & General functioning system ! ! - & Detailed functioning system 5 ' :: ! ; ) ! .. ' - & .. &! ' ! ) & .. & - ' ' . .. - ) ) :6 . ! :- & ) & ! & ) 2 & .. ' . - ' / 3 ' ' - ' - ' :<: ! ' ! 4 / ' - ) & -' -' ) - . 2. FUNCTIONING SCHEME OF INDIRECT AND POST-VENTILATED HEATERS S F2 T C1 E R M U B V F1 A EV F4 F3 % " " 6 7 ! ( 8 1 4 & .. ) (6 General functioning system ! ! - - & &! & ' ! .. ) ' ) = ' - ' ) ) Detailed functioning system 5 ' :: ! & ; ! .. & & & ' - ' . .. ! & - ) ) & ) 2 & .. 5 :6 . -! . - :- & ) ' / 3 ' ' - ' :<: -' ) / ! ' ) ! ' - ) ! ' & 3. INSTALLING THE UNIT Safety precautions ' '= = = &= = 6 ' ' . Ventilation requirements ! )- = // >2?5 ' 3 ! '= # &5 &5 + &5 &5 $/&5 / #/ @ / / / +/ / / /$// 4. ROTARY COMPRESSOR Exploded view 1 " 9 ( ) & A B ) & C % D < 7 E ' ' 4 ! 7 ' ) ) ) & ' ' 4.1 Assembling sequence " ! ' 4 ' . ! ' 2 '3 ! ' ' / ' = /# & - /& 8 & ' ' $// ' '= ' : := # / + # / $/&5 F * F ' ' ' & - ' :<: / ' - 4.2 Tuning ' : :- 2 3 ; - ! ) ' ! - & 2 ' * 9 3- / /$ # # 4.3 Cleaning the air filter ! # % $ # " " $ " $ ! ' & ! ' ' & ' & " 4 = // #// /// < ( $ / ' /// 10 5. TROUBLESHOOTING SWITCH ON Check for correct voltage rating (see data plate) +/- 10% nom. value Chech for the correct voltage on the control panel Check fuse (burn-outs, damages,etc.) THE UNIT DOES NOT START • • Check all connections Replace with a new one with identical ratings. • • See charter 6.20 Replace the control unit Check that the red lock-out warning light is not alight • Switch on “O”, wait 10 seconds and switch on “1” Check that the overheat thermostat has not been activated • • Leave the unit to cool Position on “0” and then on”1”. Check that the remote thermostat is properly connected and adjusted. Only on AP and PV models • • Check connections Turn the thermostat tap For operation without remote thermostat, check that the thermostat socket cover is correctly inserted in the socket. Only on AP and PV models • • Check the metal jumper Reinsert and block • Replace if not functioning correctly Check the burner control unit Check that following parts are working: - Motor and capacitor - Electrical cable and plug - Internal cables 11 • • Replace if not functioning See chapter 6.16 • • Tighten the oil line fittings Check for damages/craks in the oil hoses Check that the nozzle is clean • Check charter “ Cleaning the combustion head” Check that the combustion head is clean • Clean the combustion head with compressed air or a brush dipped in oil Check that the electrovalve opens after the prepurge sequence. Only on AP and PV models • • Check the electrical tester. See chapter 6.13 Check for the presence of external (spurious) lights (sunlight, lamps) • Look for – and eliminate – light reflectors due to sunrays, lamps, etc. that could disturb the flame sensor Look for fires inside the machine Check the following parts are working: • Ignition transformer • HT cables • Ignition electrode Check that the oil tank is full Check for air bubbles in the air filter THE HEATER STARTS, THE PREPURGE SEQUENCE STARTS BUT THEN THE HEATER STOPS WITHOUT IGNITION • Check that oil flows to the nozzle 12 • • Check the position of air and oil hoses on the combustion head Check that the o-ring on the nozzle is not damaged THE HEATER START, IGNITES AND THEN STOPS Check that the photocell is not damaged, clean and fixed to the combustion head • • Clean the photocell with alcohol Replace if necessary Check that the nozzle is clean • • See chapter 6.9 Replace oil nozzle • Wrong air pressure of the compressor Look for correct nozzle size on the setting chart Check the nozzle size THE HEATER STARTS, THE FLAME IGNITES BUT COMBUSTION IS NOT GOOD Measure and regulate pressure Check the nozzle is clean • • See chaper6.9 Replace oil nozzle Check that the oil filter is clean • See chapter 6.7 Check that there are no air bubbles in the fuel line • • Tighten fittings Replace the faulty pipes/hoses Wrong air pressure of the compressor • Measure and regulate pressure Oil is not correct, dirty, polluted or contains water • Empty tank and refill with correct fuel Pulsating combustion • • • 13 Check and clean oil nozzle Check if o-ring on nozzle is damaged Check that the nozzle holder is not damaged Photocell activated • • Dirty photocell: clean with alcohol No flame caused by: • Dirty nozzle • No oil THE HEATER STOPS SUDDENLY Overheat thermostatincorrectly activated • • Wrong location of overheat thermostat (after incorrect servicing, repairs, etc.) Damaged electrical connection cable OK Excessive overheating of combustion chamber (overheat thermostat activated) • • • • • • • • 14 Wrong nozzle (too large) (see specification chart) Wrong fuel pressure (too high) – see specification chart Insufficient ventilation due to motor fault Insufficient ventilation due to fan failure Blockage of airways due to dirt or foreign objects Exhaust pipe partially obstructed Combustion chamber clogged by soot (see charter 3.10) Room temperature too high 6. MAINTENANCE AND SERVICE OPERATIONS &' '* ( ' ' +' & *( ' +)' * ', ,-0 & &' ',' * * / '1 ,*' ' ((' ' *) ' ) )' * , ( * +' . ,/' ( ), ' , * /' , *1 6.1 CHECKING THE SUPPLY VOLTAGE ! ' 2 /63 ! /6 /6 ' • % & ' = • " & • " & D ' 23 & =< > - ' . 6.2 CHECKING AND REPLACING THE POWER CORD • " & • 8 ' ) ' • 8 ! • < ' = B/* D ' • 9 - • • ) ' ) ' ) ' 2 ' =# • ) • " • " & • )3 6.3 CHECKING AND REPLACING THE MOTOR • () • " & • " & - ! • 8 • 9 • • 8 &- ' & = ' $ %# ' • ) & • " • • • 9 • 8 ! • 8 ' & ' 16 ' & = ' & " ' ) • • () • 9 • ' • " - & 6.4 CHECKING AND REPLACING THE FAN • " & & & ! • 8 • • " ' = ' ) ' & ' ' • • " & ) • ) 6.5 EXHAUST GAS ANALYSIS (only for indirect heaters) 7 1 • 8 ) 4 & ' * 17 ) • 5 34 / ( '* '5 2( ) ' & & ,-3' • () 2 ' & ! ) 9 / 4 1 F ' & & " & >' & & - F ) 2 ' 3 & = " 2 ) & 2 3 ' < 9 G ) ) $ *-$ +-$ ,3 .. 2 C & - 6.7 CHECKING AND REPLACING THE FUEL FILTER ' ' 6.6 CLEANING THE TANK ! • C • 7 • 8 &= ' ' ' & & • 8 18 ' • " & - ! • 9 = • 6.8 CHECKING AND REPLACING THE FUEL HOSE " & ! & " & ' • () ' &' ' & ' • 8 • " 6.9 CHECKING REPLACING CLEANING THE NOZZLE .. .. AND • • • 2 • " • • .. < 3 & < ' .. ( 6 % $ 19 .. # % • • 3 7 ' ) 6.10 CHECKING AND CLEANING THE COMPRESSOR ! " = ' • • • ' = // #// /// % % • • () • ' 20 () ' " & ' & • ) ' % ' ' 6.11 REPLACING AND ADJUSTING THE AIR COMPRESSOR ! ' • • • () ' %# ' • ' %# • ' ' ' % • ' ! • • = 0 ) 7 ' / /# H 2 3 # " ! "" % $ " # % " # # 6 % • 21 ) ) %# ' • FIX IN THE CORRECT POSITION! • • • • ) ' ) 8 • • %# 8 " % " • ' 2 =/ /$ 3 9 0 • " • < > & ' & ) > ' & 4 6.12 CHECKING ADJUSTING VALVE ! 8 . & ' 0 7 ' • • & 4' ' 22 • • • • 0 4 ' D 4 1 THE = PRESSURE • • = " " & ! • 9 > • • 9 ' ) • 6.13 CHECKING AND REPLACING THE AIR SOLENOID VALVE (only for indirect and post-ventilation models) • = ! ! $ 4' 2 & -2/ 3 6.14 CHECKING, CLEANING CONTROLLO, ADJUSTING AND REPLACING IGNITION ELECTRODES • () • & ' " & 93: • - ' • 6 $ ' 3 " ' ' " ' • " 23 & • ' • " & ' ' • .. 0 ' • • • ! & • ) • 9 & 6.15 CHECKING AND REPLACING HIGH VOLTAGE IGNITON CABLES = • " • " • 9 • 4' • 6 & & ) ' & & • " ' & % ',' % 6=1/ $ ! % • • ! , *& ; % # $ $ ' "$ 3< % % • 9 • 8 " • 9 • 9 2 ' 8 # 6.16 CHECKING AND REPLACING THE IGNITION TRANSFORMER ) ' % # % 1 8 " # ' 24 • • () - ' " 6.17 REPLACING THE FUSE • < • () H & " • " • '= & ' • 4 • () • H 6.18 CHECKING, CLEANING REPLACING THE FLAME SENSOR • () - AND ! • 9 I & • • 25 = ' & ' - 6.19 CHECKING AND REPLACING THE SAFETY THERMOSTAT • • " ! • 9 • • & % & ' 6.20 CHECKING AND REPLACING THE FLAME CONTROL UNIT ) = ! & - ' " 8 ! 4 = ' > 2 " = 3 & ' & 3 ' " ! ' - - ' ) ' = ' ' 7 ' 7 J ' ' ! 4 ' ! 2 > 2 " ! 2) & 3 2) ' - & 3 4 ' ' & ' 26 & 3 ' ' 2' " & ' - 3 9 2 ! C & • ! • ' 9 ' '2 - & ' #/3 ' 6.21 BURNER HEAD (OLD TYPE) ! ' ' .. ' • ! & 9 9 = 27 < .. ' & & .. ' - < • • • • .. K K K K ' ' ' ' 2 L M & & ' .. 3- .. 28 7. SETTING CHARTS Indirect fired heaters + ' &' , ; = ( ) '** * >' # NF / O 3? ) = LCM & 7? ) / = <4 ) & # NF # ) '** / ', >>,' * /' &' ( * / *' / /P/ 9(C 6 D / /A7B /$/, $#O" ! & / P/ 9(C 6 D /*# A7B /$/,+ $#O" # ! & / P/ 9(C 6 D //A7B /$/, $#O" # ! & * O # NF # +O ' # Direct fired heaters + ' &' , 3? / ( ) '** * >' D # N F ,/ #O D # N F ,/ O ! & # NF / O ! & = 74 ; ! & ) '** ' / ', >>,' * /' &' ( * / *' / + P/ / 9(C 6 D / /A7B /$/, >> # * / + P/ , 9(C 6 D /$# A7B /$/,* $#O" # * / /P/ 9(C 6 D /*# A7B /$/,+ $#O" # / P/ 9(C 6 D //A7B /$/, $#O" * A1 = D 7@ A1 = <4 D # NF # +O ! & A1 30 # Direct fired heaters with post-ventilation + ' &' , ; = ( ) '** * >' # NF # >> <4)= / ) '** ! & / P/ 9(C 6 D //A7B /$/, ! & / P/ # 9(C 6 D #/A7B /$/, , O = LCM A4)= - & N F #/ O ' / ', >>,' 31 * /' &' ( * / *' $#O" # $#O" # 8. WIRING DIAGRAMS Direct fired heaters " 4 D % ' ! !4 " 32 Indirect fired heaters and direct fired heaters with postventilation " 4 D % (6 ' ! !4 " !B 33