Assembly and First Use

3.2. Gas-fired heater

The heater housing, especially the burner stones and concrete, must be kept dry at all times.
When the stones and concrete become wet, let them dry by placing an external heat source
inside the heater until the stones and concrete are dry.

3.2.1. Construction build up

• Drill the holes for the anchor bolts.

• Place the heater support feet.
• Place the heater housing in the correct height to the conveyor and level it with filling
plates if necessary. The heater housing is provided with crane hooks. Do not use any
other part of the heater for hoisting purposes.

Project 383 Chapter 3 - Page 71

 Assembly and First Use

3.2.2. Piping assembly

The piping must be mounted on the heater housing in the correct order:

Air supply tube Air manifold

Gas manifold

Gas supply tube

Blower

Air piping
towards burner

Gas piping
towards burner

Heater housing Burner

Figure 3.3: Piping assembly

• Mount the burners in the heater housing.

• Mount the temperature sensor on top of the housing.
• Place the gas manifold on the heater, do not yet attach the tube to the housing.
• Place the air manifold on the heater, do not yet attach the tube to the housing.
• Assemble the piping between the burners and the air manifold.
• Mount the air manifold to the heater housing.
• Assemble the piping between the gas manifold and the burners.
• Mount the gas manifold to the heater housing.

Project 383 Chapter 3 - Page 72

 Assembly and First Use

• Connect the air supply tube to the air manifold.

• Connect the pressure ratio controllers to the air piping.
• Place the blower on the anti-vibration elements and mount the flexible hose.
• Connect the heater to a chimney and connect the gas bleed from the safety relief valve
to the chimney.

3.2.3. Adjusting / initial operation

• Check all gas tubes, flanges and seals for leakage using compressed air and a foam
creating liquid. The compressed air pressure may not exceed 4 Bar. Close the gas
valves just before the burners and adjust the gas pressure governor temporary to the
maximum pressure.
• When this test has passed, connect the gas supply tube to the gas manifold.
• Protect the conveyor wheels, wheel bearing and any other non-heat resistant material
near the heater with insulation material or wet cloth. The ceramic cloth used for the
heater seals is very suitable for this purpose.
• Open all manually operated valves.
• Open the chimney.
• Check if the gas supply to the gas pressure governor is at least 200 mBar, but does
not exceed 4 Bar.
• Mount a hose with a manometer (0-100 mBar) on the gas nipple at the burner.
• Mount a hose with a manometer (0-100 mBar) on the air nipple at the burner.

For more information on how to measure the pressure on the burner, refer to the user
manual in part 4, tab 2.

Project 383 Chapter 3 - Page 73

 Assembly and First Use

Adjusting the air supply:

1) Remove the cover from the servo motor of the butterfly valve just after the ventilator.

2) Use the manual / automatic switch to set the motor in manual mode.
Manual / automatic switch
Manual operating switch

Figure 3.4: Servo motor

3) Turn the MAINSWITCH ON.

4) Press the button FAN ON and check the rotation direction of the ventilator. The
rotation direction is indicated by an arrow.

When the ventilator runs in the wrong direction, approximately 40% of the normal
capacity is still reached.

5) Use the manual operating switch to open the butterfly valve until an air pressure of 36
to 41 mBar is present at each burner. An air pressure of 36 mBar is required to obtain
maximum output power.

6) Adjust the cam of the servo motor to let the servo motor stop at this maximum
butterfly valve opening. Use a screwdriver/hexagon key to adjust the cam. Do not use
excessive force to avoid damage.

Project 383 Chapter 3 - Page 74

 Assembly and First Use

Screwdriver Cam

Figure 3.5: Cam adjustment

7) Check the air pressure at each burner. When necessary, slightly close the pressure
regulating valve just before the burner.

8) Use the manual operating switch to close the butterfly valve until an air pressure of 2
to 5 mBar is present at each burner. This air pressure is required to let the burners run
at idle power.

9) Adjust the cam of the servo motor to let the servo motor stop at this minimum
butterfly valve opening. Use a screwdriver/hexagon key to adjust the cam. Do not use
excessive force to avoid damage.

The servo motor can now be opened and closed manually from 0% to 100% air pressure for
the burner.

Subsequently, the burner controller must be configured according to the electrical diagrams.
Also refer to part 4 tab 2 for additional information on the controller.

Project 383 Chapter 3 - Page 75

 Assembly and First Use

Figure 3.6: Controller configuring procedure

10) The potentiometer of the butterfly valve can be checked when the burner controller is
set to manual mode. When the butterfly valve is opened, the displayed value should
increase, when the valve is closed, the value should decrease.

Project 383 Chapter 3 - Page 76

 Assembly and First Use

11) To adjust the 0% setting (idle power), manually close the butterfly valve to the
minimum opening. The controller must be in manual mode.

12) To adjust the 100% setting (full power), manually open the butterfly valve to the
maximum opening. The controller must be in manual mode.

13) Adjust the pressure switch just after the servo motor driven butterfly valve to 2.5
mBar.

14) Turn the ventilator OFF.

Project 383 Chapter 3 - Page 77

 Assembly and First Use

Adjusting the gas supply:

Safety relief valve High and low pressure switches

Safety shut-off valve Pa Motor valve Tightness control

Pi pressure switch

Gas pressure governor

Gas filter

Gas valve

1) Check if the correct reddish-brown spring (pressure range 60-170 mBar) is placed in
the safety shut-off valve (JSAV).

2) Check if the correct black spring (pressure range 70-90 mBar) is placed in the gas
pressure governor (VGBF).

3) Check if the correct blue spring (pressure range 70-170 mBar) is placed in the safety
relief valve (VSBV).

4) The safety shut-off valve and the safety relief valve must be adjusted according to the
following graph. Refer to part 4, tab 2 on how to adjust these devices.

Project 383 Chapter 3 - Page 78

 Assembly and First Use

5) Adjust the low pressure switch to approximately 10-40% of Pa.

Adjust the high pressure switch to a value between Pa and the maximum of 150
mBar.

6) Adjust the tightness control pressure switch to 0.5 Pa.

Starting of the burners:

Also refer to the operating instructions (chapter 6) on how to start and operate the heater
control cabinet.

Air butterfly valve

Gas valve

Air pressure manometer

Gas pressure
regulating valve
Solenoid valve
Gas pressure manometer
Ratio controller

Air pressure regulating butterfly valve

1) Open the chimney.

2) Open the gas valve towards the heater.

3) Open the gas valves and the air butterfly valves towards each burner.

4) Turn the MAINSWITCH ON.

5) Press the button CONTROL ON.

6) Press the button FAN ON.

7) Press the button BURNER CONTROL ON.

Project 383 Chapter 3 - Page 79

 Assembly and First Use

Each time the burner control is turned on, the tightness control is executed by closing the
motorised valve in the gas supply tube and closing the solenoid valves in the gas manifold.
Next, the pressure is relieved by bleeding the gas off by shortly opening the solenoid valve
just after the pressure switch. After closing of this solenoid valve, the pressure switch
measures if the pressure rises. When the pressure rises, a leak is present in the motorised
valve and the lamp ALARM / RESET TIGHTNESS lights up. When pressure does not rise,
the test is successfully executed and the burners can be started.

8) Adjust the burner controller in manual mode to approximately 10-40% (4-14 mBar air
pressure at the burner).

9) Fully open the gas pressure regulating valve of the first burner that must be started.

10) Select the burner with the corresponding switch BURNER ON. This will open the
solenoid valve towards the burner.

During the startup procedure, the safety shut off valve may trip. Reset or readjust the
safety shut off valve when necessary.

As soon as air and gas pressure are within setpoint range, the lamp INITIALISING goes out.
The selected burner should now ignite automatically. As soon as the burner is lit, the
corresponding ON lamp lights up.

It may take several times before the burner ignites, due to air in the gas tubing. When the
burner does not ignite after trying several times, check the following:

• If all signals are present correctly inside the control cabinet. A small indication panel
is mounted inside the control cabinet, on which the current status of the various
pressures and the servo motor driven air valve position is displayed. Check the wiring
and connections when faults appear.
• If the correct solenoid valve opens. When the correct solenoid valve does not open,
the gas pressure at the burner will be zero.
• If the solenoid valve opens fast enough. Adjust the damping of this valve when
necessary.
• If the ignition and the ionisation are connected correctly: Z=ignition and I=ionisation.
Change the spark plug boots when necessary. The ignition spark plug boot must be
the one with the suppression resistor.
• Check if the safety shut off valve is not tripped. Increase the pressure setting slightly
when the safety shut off valve is tripped.

The burner can now be started again.

Project 383 Chapter 3 - Page 80

 Assembly and First Use

11) When the burner burns, the 1:1 ratio as supplied by the ratio controller must be fine-
tuned by choking the gas pressure regulating valve or the air pressure regulating
butterfly valve.
The flame must be evenly blue. When yellow flames are present, choke the gas
pressure regulating valve.
When the flame is dark blue, choke the air pressure regulating butterfly valve.

Attention: A yellow flame produces poisonous carbonmonoxide

and leaves a small percentage of gas unburned.

Chocking the gas pressure has no influence on the air pressure.

Chocking the air pressure with the air pressure regulating butterfly valve results in an
increased gas pressure (caused by increased air pressure before this valve, measured
by the ratio controller).

Choking the air pressure with the air butterfly valve (mounted before the ratio
controller connection) results in a decreased air and gas pressure. The ratio at the
burner stays approximately the same.

12) Increase the heater output power slowly, keeping constant track of air and gas
pressure at the manometers connected to the burner. When the burner controller is set
to 100%, the gas pressure at the burner must be 31 mbar.

13) Adjust the gas pressure when this value is incorrect by adjusting the gas pressure
governor spring tension.

14) Turn the burner OFF

The other burners must be adjusted in the same way.

Project 383 Chapter 3 - Page 81

 Assembly and First Use

The heater must now be warmed up evenly to remove chemically bound and/or locked up
water residues. The slower the heater is warmed up, the better. Too fast a warming up will
result in cracking of the concrete or the burnerstones. A practical indication of minimum
warming-up time is given by the following graph. When the heater has been stored at a high
relative humidity (>80 %), warming up time must be prolonged with 20%.

Figure 3.7: Drying graph heater.

Use the new, uncut seals to close the entrance and exit of the heater and start one burner to let
the heater warm up. After one or two hours, start another burner and turn the previous burner
off. In this way, all burners can burn for some time without overheating the heater.
Subsequently, all burners may be started.
The drying procedure may be divided over two days. Close the chimney after turning off the
heater at the end of the first day, to keep the heat inside as much as possible.

When the heater is running correctly, adjust the purge time and the valve closing time on the
timers inside the control cabinet:
Purge time: 3 minutes Timer number 101K3
Closing time: 1 minute Timer number 101K5

Project 383 Chapter 3 - Page 82