COMBAT ECO20A User manual

1code HG0140.00GB-M ed.A-1507
ECO
Operating, Installation and Maintenance Manual
CONDENSING WARM AIR HEATER ECO
GB
This manual cannot be copied in part or in full for disclosure to third parties without the prior written consent by Combat HVAC Limited

2
code HG0140.00GB-M ed.A-1507 ECO
WARM AIR HEATER ECO
Declaration of Conformity
COMBAT HVAC LIMITED
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands, WS10 7SH UK
Telephone: [phone]
Fax: [phone]
www.combat.co.uk
With this document we declare that the unit:
Model: Warm air heater ECO, ECOxxEA, ECOxxB, ECOxxBE
has been designed and manufactured in compliance with the prescriptions of the following EC Directives:
Machinery Directive 2006/42/CE
Gas Appliance Directive 2009/142/CE (ex 90/396/CE)
Electromagnetic Compatibility Directive 2004/108/CE or 2014/30/UE
Low Voltage Directive 2006/95/CE or 2014/35/UE
If the unit is to be installed into an equipment (combined), the manufacturer disclaims any responsibility if this
equipment is not previously declared compliant with the requirements specied in IIB Enclosure of the above said
Machinery Directive.
COMBAT HVAC LIMITED
CODE SERIAL NUMBER

3code HG0140.00GB-M ed.A-1507
ECO
WARM AIR HEATER ECO

4
code HG0140.00GB-M ed.A-1507 ECO
WARM AIR HEATER ECO

5code HG0140.00GB-M ed.A-1507
ECO
WARM AIR HEATER ECO
INDEX
SECTION 1. GENERAL CAUTIONS ................................................................... 6
SECTION 2. SAFETY INSTRUCTIONS ............................................................. 6
2.1 Fuel ...............................................................................................
6
2.2 Gas Leaks...................................................................................... 6
2.3 Power Supply................................................................................. 7
2.4 Operation ......................................................................................
7
2.5 Maintenance .................................................................................. 7
2.6 Transport and Handling ................................................................. 7
2.7 Packaging ...................................................................................... 7
SECTION 3. TECHNICAL FEATURES ............................................................... 8
3.1 Technical Data ............................................................................... 9
3.2 Dimensions .................................................................................... 10
SECTION 4. USER'S INSTRUCTIONS .............................................................. 12
4.1 Operating Cycle ............................................................................. 12
4.2 Accessories ................................................................................... 12
4.3 Interface Panel............................................................................... 14
4.4 Reset ............................................................................................. 15
4.5 Set-up ........................................................................................... 16
SECTION 5. INSTALLATION INSTRUCTIONS................................................... 17
5.1 General Installation Instructions .................................................... 17
5.2 Installation...................................................................................... 17
5.3 Condensation Drainage ................................................................. 19
5.4 Connections to the Flue................................................................. 20
5.5 Electrical Connections ................................................................... 26
5.6 Modulation PCB Parameters ......................................................... 28
5.7 Analysis of lockouts - Faults ......................................................... 31
SECTION 6. GAS CONNECTION ....................................................................... 33
SECTION 7. SERVICING INSTRUCTIONS......................................................... 34
7.1 Country Table - Gas Category ...................................................... 34
7.2 Gas Settings Table......................................................................... 35
7.3 ConguringwithLCDDisplay ........................................................ 38
7.4 Startingupforthersttime............................................................ 39
7.5 Analysis of combustion .................................................................. 39
7.6 Conversion to LPG ........................................................................ 40
7.7 Conversion to gas G25 - G25.1..................................................... 41
7.8 Conversion to gas G2.350............................................................. 41
7.9 Replacing the gas valve................................................................. 42
7.10 Replacing STB and NTC ............................................................... 42
7.11 Replacing the modulation PCB...................................................... 42
SECTION 8. MAINTENANCE.............................................................................. 43
SECTION 9. WIRING DIAGRAMS ...................................................................... 44
SECTION 10. LIST OF SPARE PARTS................................................................. 45
10.1 Parts for the electrical panel .......................................................... 45
10.2 Parts for the burner unit ................................................................. 46

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code HG0140.00GB-M ed.A-1507 ECO
WARM AIR HEATER ECO
1. GENERAL CAUTIONS
This manual is an integral part of the product and must always
accompany it.
Should the equipment be sold or passed on to someone else,
always make sure that this manual is supplied with the equip-
ment for future reference by the new owner and/or installer.
The manufacturer shall not be held civilly or criminally respon-
sible for injuries to people or animals or damages to things
caused by incorrect installation, calibration and maintenance
or by failure to follow the instructions contained in this manual
orbyoperationscarriedoutbyunqualiedstaff.
This product must be used only for the applications for which
it was designed or approved. Any other use must be regarded
as hazardous.
During the installation, operation and maintenance of the equip-
ment described in this manual, the user must always strictly
follow the instructions given in all the chapters of this operating
and maintenance manual.
----------------------------------------------------------------------------------
The warm air heater must be installed in compliance with
current regulations, according to the manufacturer's instruc-
tions and by suitably qualied staff. who has the technical
knowledge in the heating sector.
----------------------------------------------------------------------------------
Conversion between different types of gas and maintenance
operations must be carried out before being switched on, and
only by suitably qualified staff. Technical Service Centres
certified by current and older standards.
For more information, visit our Web site
www.combat.co.uk or contact the manufacturer directly.
The warranty conditions for this equipment can be found in the
Combat HVAC Limited Terms and Conditions Of Sale
Reference standards (only applies to Italy):
• Ministerial Decree No. 74 of 12/04/96;
• Ministerial Decree No. 37 of 22/01/2008;
•UNI-CIG 7129-1, -2, -3, -4 standard, which regulates the
installationofnaturalgasredequipment;
•UNI-CIG 7131 standard, which regulates the installation
ofLPGredequipment;
•Law No. 10/91 and Presidential Decree No. 412/93 on
reducing energy consumption;
• Legislative Decree 192/05 of 19/08/2005;
• Legislative Decree 311 of 29/12/2006;
•UNI CIG 11528:2014 standard "Design, installation and
commissioning gas systems with heat output higher than
35 kW".
These standards may be subject to changes and/or additions.
2. SAFETY INSTRUCTIONS
This chapter describes the safety instructions to be
followed by the installer.
2.1. Fuel
Before starting up the heater, make sure that:
• the gas mains supply data is compatible with the data
stated on the dataplate
•thecombustionairintakeducts(whenfitted)andtheflue
exhaustpipesarethosespecifiedbythemanufacturer;
• the combustion air is supplied in such a way as to avoid
even partial obstructions of the intake grille (caused by
leavesetc.);
• the fuel intake internal and external seal is checked during
the testing stage, as required by applicable standards;
• the heater is supplied with the same type of fuel it has
been designed for;
•the system is correctly sized for such flow rate and is
fitted with all safety and monitoring devices required by
applicable standards;
• the inside of the gas pipes and air distribution ducts for
ducted heaters has been thoroughly cleaned;
•thefuelflowrateissuitableforthepowerrequiredbythe
heater;
•thefuelsupplypressureisbetweenthe rangespecified
on the dataplate.
2.2. Gas Leaks
If you smell gas:
• do not operate electrical switches, telephones or any other
object or device that could produce sparks;
•immediatelyopendoorsandwindowstocreateanairflow
to vent the gas out of the room;
• close the gas valves;
•Contact your gas provider

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WARM AIR HEATER ECO
If the equipment is not used for long periods, shut the gas sup-
ply off through the gas shut off valve and disconnect it from
the power supply.
If the heater is to be put out of service, in addition to the above
operations, potential sources of hazard on the unit must be
removed.
It is strictly forbidden to obstruct the Venturi pipe inlet, located
on the burner-fan unit, with your hands or with any other objects.
Anyobstructioncouldcauseabackrefromthepremixedburner.
2.6. Transport and Handling
The heater is delivered fastened to a pallet and covered with a
suitably secured cardboard box.
Unload the heater from the truck and move it to the site of
installation by using means of transport suitable for the shape
of the load and for the weight.
If the unit is stored at the customer’s premises, make sure a
suitable place is selected, sheltered from rain and from excessive
humidity, for the shortest possible time.
Any lifting and transport operations must be carried out by
skilled staff, adequately trained and knowledgeable on the
working procedures and safety regulations.
Once the equipment is moved to the correct position, the un-
packing operation can be started.
2.7. Packaging
The unpacking operation must be carried out by using suitable
tools or safety devices where required. Recovered packaging
materials must be separated and disposed of according to ap-
plicable regulations in the country of use. While unpacking the
unit, check that the unit and all its parts have not been damaged
during transport and match the order. If damage has occurred
or parts are found to be missing, immediately contact the sup-
plier. The manufacturer is not liable for any damages occurred
during transport, handling or unloading.
2.3. Power supply
The equipment must be correctly connected to an effective
earthing system, made in compliance with current regulations
(CEI64-8,onlyappliestoItaly).
Cautions
• Check the effectiveness of the earthing system and, if
required,calloutaqualifiedengineer.
• Check that the mains power supply is the same as the
power input stated on the equipment dataplate and in
this manual.
• Do not swap the neutral with the live wire.
•Theelectricalsystemand,morespecifically,thecablesec-
tion, must be suitable for the equipment maximum power
input , shown on the dataplate and in this manual.
Do not pull electric cables and keep them away from heat sources.
---------------------------------------------------------------------------------
NOTE: It is compulsory to install, upstream of the power
cable, a fused multi-pole switch with contact opening wider
than 3mm.
The switch must be visible, accessible and less than 3m
away from the control board.
All electrical operations (installation and maintenance)
must be carried out by suitably qualied staff.
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2.4. Operation
Do not allow children or inexperienced people to use any electri-
cally powered equipment.
The following instructions must be followed:
•do not touch the equipment with wet or damp parts of your
body and/or with bare feet;
•do not leave the equipment exposed to the elements (rain,
sunetc....)unlessitisadequatelyprotected;
• do not use the gas pipes to earth electrical equipment;
• do not touch the hot parts of the heater, such as the flue
gas exhaust duct;
•donotwettheheaterwithwaterorotherfluids;
• do not place any object over the equipment;
• do not touch the moving parts of the heater:
2.5. Maintenance
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Maintenance operations and combustion inspections must
be carried out in compliance with current standards.
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Before carrying out any cleaning and maintenance operations,
isolate the heater from the mains power supply via the switch
located on the electrical system and/or on the shut-off devices.
If the heater is faulty and/or incorrectly operating, switch it off
and do not attempt to repair it yourself, but contact the local
Technical Service Centre.
All repairs must be carried out by using genuine spare parts.
Failure to comply with the above instructions could compromise
the safety of the equipment and invalidate the warranty.

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code HG0140.00GB-M ed.A-1507 ECO
WARM AIR HEATER ECO
DONOTCOVER IT WITHYOUR HAND OROTHEROBJECTS!
WARNING: Before switching on the heater, open the lou-
vres by at least 45°
HG0140.00_IM_001
3. TECHNICAL FEATURES
The ECO series modulating warm air heaters have been de-
signed for industrial and commercial environments.
The heater PCB continually modulates the heat output between
the minimum and maximum power, according to heating re-
quirements.
The premixing and modulating technology allows the heater to
achieveefciencyabove108%oftheL.C.V.
The heater can operate independently; it can be started up by
simply connecting it to the power mains and to the gas mains.
The heaters' heat output ranges from 5 to 97kW.
The units can be controlled:
• from an external time/temperature control;
• externally with the modbus (through SmartControl, Smart.
netorSmart.web);
• proportionally, with a 0-10 Vdc external control.
The heat exchanger complies with the manufacturing require-
ments for condensing warm air heaters, and with standards
EN1020 and EN1196.
The combustion chamber and the surfaces of components where
condensation occurs (such as the pipe bundle and exhaust
hood),aremadeofAISI441,inordertoprovidehighresistance
to condensation and temperature.
The following table illustrates the types of stainless steels used:
USA-AIS EN-No. COMPOSITION
AISI 441 1.4509 X2 CrTiNb 18
The innovative design and the large heat exchanging surface
of the combustion chamber and of the tubes ensure optimum
efciencyanddurability.
The burner is made entirely of stainless steel with special me-
chanical solutions to ensure optimal reliability and performance
levels, as well as high thermal and mechanical resistance.
The control located on the front panel allows the service centre
to check and view the working phases and identify any faults
that may have occurred.
Inherent Safety
The performance increase at minimum power is achieved by
using a sophisticated air/gas mixing technique and by adjusting
at the same time the combustion air and the fuel gas.
This technology increases the heater safety as the gas valve
suppliesthefuelaccordingtotheairow.Unlikewithatmos-
pheric burners, the CO2proportion remains constant throughout
theheateroperatingrange,allowingittoincreaseitsefciency
when the heat output reduces.
If there is no combustion air, the valve will not supply gas; if
thecombustionairowreduces,thevalvewillautomatically
reducethegasowyetwillkeepits combustionparameters
at optimal levels.
Low emissions
The premixed burner, in combination with the air/gas valve,
ensures "clean" efcient combustion with low emissions of
pollutants.

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ECO
WARM AIR HEATER ECO
Model: ECO20A ECO34A ECO45A ECO65A ECO80A ECO105A
Type of equipment B23P - B53P - C13 - C43 - C53 - C63
ECcertication PIN. 0476CQ0451
NOx Class Val 5
Heater Performance
min max min max min max min max min max min max
Burnerheatoutput(Hi) kW 4.75 19.00 7.60 34.85 8.50 42.00 12.40 65.00 16.40 82.00 21.00 100.00
Useful heat output kW 4.97 18.18 8.13 33.56 8.97 40.45 13.40 62.93 17.77 80.03 22.77 97.15
EfciencyHi(NetC.V.) % 104.63 95.68 106.97 96.30 105.50 96.30 108.06 96.82 108.35 97.60 108.40 97.15
EfciencyHs(GrossC.V.) % 94.26 86.20 96.37 86.76 95.07 86.76 97.36 87.22 97.62 87.93 97.68 87.52
Fluelosseswithburneron(Hi) % 0.4 4.3 0.6 3.7 0.5 3.7 0.2 3.2 0.3 2.4 0.2 2.8
Fluelosseswithburneroff(Hi) % <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
Losses in enclosure (1) 0% 0% 0% 0% 0% 0%
Max. condensation (2) l/h 0.4 0.9 1.1 2.1 3.3 2.7
Flue gas emissions
Carbonmonoxide-CO-(0%ofO2)(3) ppm < 5 < 5 < 5 < 5 < 5 < 5
Nitrogenoxides-NOx-(0%ofO2)(4) 38 mg/kWh -
22 ppm
42 mg/kWh -
24 ppm
33 mg/kWh -
19 ppm
39 mg/kWh -
22 ppm
32 mg/kWh -
18 ppm
41 mg/kWh -
23 ppm
Availablepressureatue Pa 80 90 100 120 120 120
FLUE GAS temperature, CO2contentandmaximumfluegasflowrate:seegastablesonpage37andonthe
fol-lowing pages
Electrical Data
Power supply V 230 Vac - 50 Hz single-phase
Power input W 147 180 270 310 280 310 425 510 500 613 650 750
Power input in stand-by W <5
Ingress Protection Rating IP IP 20
Operating Temperatures °C from -15°C a +40°C - for lower temperature, a burner housing heating kit is required
Storage Temperatures °C from -25°C to +60°C
Connections
Ø gas connection (5) GAS UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4"
UNI/ISO 228/1-
G 3/4" (6)
UNI/ISO 228/1-
G 3/4" (6)
Ø Combustion air intake/exhaust pipes mm 80/80 80/80 80/80 80/80 100/100 (7) 100/100 (7)
Air ow rate
Airowrate m3/h 2700 4300 4500 7800 9000 11100
Air temperature increase °C 5.28 19.30 5.42 22.37 5.73 25.74 4.92 23.13 5.66 25.49 5.89 25.09
Number and diameter of fans 1 x Ø350 1 x Ø 450 1 x Ø450 2 x Ø400 2 x Ø450 3 x Ø400
Fans speed rpm 1370 1370 1370 1370 1370 1370
Soundpowerlevel(Lw)(8) dB(A)
Weight
Net weight kg 70 77 98 125 143
Weight when packaged kg 85
NOTES:
(1)Thelossesfromtheenclosuremustberegardedaszeroastheheaterisinstalledinaheatedenvironment.
(2) Max..condensationproducedacquiredfromtestingat30%Qn.
(3) Valuereferencedtocat.H(G20)
(4) WeightedvaluetoEN1020ref.toclassH(G20),referredtoHi(L.C.V.).
(5)Thegaslinemustbemeasuredbytakingintoaccountthelengthofthepipesandnottheheaterdiameter.
For countries requiring an ISO connection different from the one shown above, an adaptor will be supplied.
(6) FortheECO80AandECO105Amodels,theminimumgassupplyductdiametermustbeUNI/ISO 228/1- G 1".
(7) Ø100/100obtainedbyusingadaptorssuppliedasstandard.
(8) Measuredatadistanceof5mfromthemachine.
3.1. Technical Data

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code HG0140.00GB-M ed.A-1507 ECO
WARM AIR HEATER ECO
Mod.
ECO
Overall dimensions Inlet Shelf Supply GAS Packaging
B H L HB LB IS ID ØG GO GV Bi Li Hi Hbi
ECO20A
500
690
795
520
490 395 400
3/4''
180 255
810 890 850 123
ECO34A
985 680 490 495
810 1080 850 123
ECO45A
765 595
810 1080 920 123
ECO65A 1310 1010 655 660 810 1410 920 123
ECO80A
845
1515
675
1180 770 745
210 275
810 1610 1040 123
ECO105A 1740 1410 895 845 810 1810 1040 123
Bi
Li
Hbi
Hi
145
HG0140.00_C2_001
HG0140.00_C2_001
HG0140.00_C2_001
HG0140.00_C2_001
IS ID
HB
L
108
LB
62
H
730
515
B
125
TO
A
S
F
AO
A
GV
GO
TVAV
S
F
G
HG0130.00 A 041
3.2. Dimensions