GoGaS Goch VARIOMAX 06 / 1 Manual

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Doku VARIOMAX_engl_06 12 June. 2012
Goch GmbH & Co. KG
Installation, Operation and Service Instructions
VARIOMAX
(one-stage)
(two-stage)
VARIOMAX 06 / 1
VARIOMAX 06 / 2
VARIOMAX 12 / 1
VARIOMAX 12 / 2
Read and thoroughly understand these instructions before
attempting any installation.
Should you have any questions regarding these instructions, please contact:
GoGaS Goch GmbH & Co. KG
Zum Ihnedieck 18
D-44265 Dortmund
Germany
Tel.: [phone]
Fax.: [phone]
GoGaS Goch GmbH & Co. KG Tel:: [phone] E-Mail: [e-mail]
Zum Ihnedieck 18 Fax: [phone] Internet: www.gogas.com
D-44265 Dortmund
CE-0085AU0204
Product Identification No.

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Goch GmbH & Co. KG
Preface
Intended Use
The GoGaS VARIOMAX high intensity heater is intended to be used for the heating
of commercial and industrial covered open spaces and halls. The appliance must be
protected from splash water. An appropriate ventilation of the halls is required,
according to local standards and regulations. European standards require a positive
air displacement of 10 m3per installed kWh.
The Technology
The VARIOMAX is a high-quality product and is available in two ratings (6 kW and 12
kW). The modern injector burner allows for either one- or two-stage operation. The
two-stage operation is achieved by means of a double nozzle (100% full load / 50%
half load at constant manifold pressure). A special double layered radiation grille
ensures a stable operation in windy conditions and increases the radiant efficiency.
The combustion chamber, control unit and gas train are protected by a case.
Controls
The VARIOMAX can be operated as a one- or a two-stage heater. For two-stage
heaters, a double nozzle allows two-stage regulation under constant gas pressure.
The gas flow is controlled by changing nozzle orifice size.
This instructions manual is subject to change without notice.

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Goch GmbH & Co. KG
Table of Contents
1. Safety Considerations.................................................................................................... 4
2. General Information........................................................................................................ 5
3. Energy supply ................................................................................................................ 6
4. Heater Mounting Instructions.......................................................................................... 7
5. One-stage Heater Startup .............................................................................................10
6. Two-stage Heater Startup .............................................................................................11
7. Troubleshooting ............................................................................................................13
8. Service and Maintenance..............................................................................................14
9. Changeover to different gas type...................................................................................15
10. Setting Nozzle Pressure for One- and Two-Stage Heaters........................................16
11. Minimum Mounting Height .........................................................................................17
12. Minimum Clearance to Combustibles.........................................................................18
13. Nozzle Pressures Table.............................................................................................19
14. Technical Data...........................................................................................................19
15. Illustration: Connection of the Control Unit.................................................................20
16. Spare Parts List.........................................................................................................21

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Goch GmbH & Co. KG
1. Safety Considerations
Used Symbols
Following warning icons are used to indicate hazards:
Warning - failure to comply may result in personal injury and property
damage.
Warning about working with electrical equipment.
Only the manufacturer or an approved installing or service company are
allowed to perform work on this heater, complying with the local standards.
This heater must be installed and serviced only by the manufacturer or by
personnel, who have been trained, qualified and understand all applicable
codes. In Germany, only the manufacturer or an approved installing or service
company are allowed to perform work on this heater, complying with the
DVGW-Arbeitsblatt G 676.

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Goch GmbH & Co. KG
This appliance must be installed in accordance with
current connection and installation regulations and may
only be used in adequately ventilated rooms. The
installation and operating instructions must be thoroughly
read and understood before installation, startup and
service.
Before installation it must be checked if local gas
distribution, gas type, gas pressure and the settings of the
appliance are compatible with each other.
2. General Information
GoGaS infrared heaters are manufactured in accordance with DIN EN 419. Each
appliance is subjected to a function test before it leaves the factory and is preset to
the relevant gas type. When installing and operating radiant heaters, the local
regulations and guidelines must be complied with. In Germany, these are:
Aufstellung von Strahlungsheizungsanlagen
DVGW Arbeitsblatt G
638/I
(Installing Radiant Heating Systems)
Technische Regel für Gasinstallation
DVGW Arbeitsblatt
G 600 TRGI 1986/96
(Technical Rules for Gas Installations)
Technische Regel Flüssiggas
TRF 1996
(Technical Rules for Liquid Gas)
Technische Regel für die mechanische Abführung der Abgase von
Feuerstätten
DVGW G 660
(Technical Rules for Mechanical Elimination of Heating System Flue
Gas)
Regeln für Berechnung des Wärmebedarfes von Gebäuden
DIN 4701
(Rules for Calculating Heat Load for Buildings)
Sicherheiztechnische Ausrüstung von Heizungsanlagen
DIN 4751
(Safety-related Equipment for Heating Systems)
Gasfeuerungen in Heizungsanlagen
DIN 4756
(Gas Firing Equipment in Heating Systems)
Bestimmungen für das Errichten von Starkstromanlagen
VDE 0100
(Regulations for High Voltage Systems Installation)
Allgemeine Anforderung für die elektr. Sicherheit
VDE 0702
(General Requirements for Electrical Safety)
Technische Anschlussbedingungen Der örtlichen
Energieversorgungs- Unternehmen
TAB
(Technical Requirements of the Local Power Supply Company)
Landesbauordnung
LBO
Regional Building Regulations
Feuerungsverordnung der Länder
FeuVO
(Regional Firing Installaitons Regulations)

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Goch GmbH & Co. KG
3. Energy supply
Gas connection: R ½ male thread
Gas supply line pressures
Connection
Maximum
Minimum
Nat. gas G20
100 mbar
20 mbar
Nat. gas G25
100 mbar
20 mbar
Propane G31
100 mbar
60 mbar
Gas consumption: see Ch. 14. “Technical Data”
Electrical connection
Alternating current AC Voltage 230 V, 50Hz with L, N and PE
Power consumption: 12 W for one-stage heaters
32 W for two-stage heaters
Parts Overview VARIOMAX 6
Item. 1
6 kW Heater
Item. 2
Wall Bracket
Item Qty. Descriotion Size DIN / EN Illustration
3 4 Pcs. Washer 6,4 125
4 4 Pcs. Hexagonal nut M 6 24034
5.1 1 Pcs.. Ball valve 1/2"
5.2 1 Pcs. Screw connection 1/2"

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Goch GmbH & Co. KG
Parts Overview VARIOMAX 12
4. Heater Mounting Instructions
The VARIOMAX heater is preset in the factory and is delivered ready to install. The
heater is positioned at a 45° mounting angle which may not be changed.
We recommend first mounting the heaters and afterwards installing the gas piping.
The ball valve can be positioned in such a way that it is easily accessible, but hidden
from sight. In case of a radio remote control operation, the receivers should be
positioned in such a way that the radio waves are not covered by the heater body.
For facilitating the mounting, the heater is equipped with a mounting plate.
Item 1
12 kW Heater
Item 2
Wall bracket
Item
Qty.
Description
Size
DIN / EN
Illustration
3
4 Pcs.
Washer
6,4
125
4
4 Pcs.
Hexagonal nut
M 6
24034
5.1
1 Pcs.
Ball valve
1/2"
5.2
1 Pcs.
Screw connection
1/2"
Grundplatte
375 777 12 kW 627
408 6 kW
Wall mounting plate

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Goch GmbH & Co. KG
Mounting Procedure:
Place the mounting plate on the wall, marking the position of the holes.
Fasten to wall.
Position the heater on the bolts of the mounting plate
Put the washer (3) and the hexagonal nut (4) on the upper bolts
Without using tools, screw the hex. nuts until the end
Now screw the lower washer (3) and the hex. nut (4)
Screw all six hex. nuts tight, using tools.
Gas Connection:
Put sealant on the ½“ fitting of the gas hose and tighten the (5.2) screw
connection.
Gas Hose Connection
5.2

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Goch GmbH & Co. KG
Install ball valve on the gas pipe.
Close the ball valve.
Connect the (5.2) screw connection to the ball valve
Electrical Connection:
The switching and control system is designed for an input voltage of 230 V, 50 Hz
alternating current with ground lead and operates in the VDE1-approved tolerance
range of -15% to +10%. Power consumption 12 W (32 W for two-stage heaters).
Input voltage to be checked before startup.
One-stage Electrical Connection
Lead the three-wire cable of the heater to the power supply and connect.
Wiring / Connection cables
Brown or “1”= L
Blue or “2”= N
Green / yellow = PE
Two-stage Electrical Connection
Lead the four-wire cable of the heater to the four-wire power supply and
connect.
Wiring / Connection cables
Brown or “1”= L
Blue or “2”= N
Black or “3”= two-stage switching (terminal 4 in controller)
green / yellow = PE
Ensure correct polarity of electric connection. Make sure to ground the
system.
1Verband Deutscher Elektrotechniker

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Goch GmbH & Co. KG
5. One-stage Heater Startup
a) Open the gas valve and measure the gas supply line pressure at the test socket
(see Combination Valve –Top View) The connected gas supply pressure must
comply with the specifications in Ch. 3 “Energy Supply”, otherwise the startup must
be interrupted.
Perform leak test at the ball valve and the screw connection up to the gas hose.
In case of appropriate gas supply pressure, the heater may be turned on using the
respective switching system (either manual switchbox or switching- and control
system).
Measure the gas supply pressure again during full load operation. If the
gas pressure is too low, the operation must be interrupted. After
measurement, close gas pressure test socket.
b) Operating Sequence of the SG 300 Controller
Connect electricity to unit.
1.5 sec after switching on, the igniter creates a high-voltage spark and,
simultaneously, the solenoid gas valve opens.
- If after an ignition attempt of max. 30 sec. no flame is recognized by the
ionization flame monitoring module, the ignition stops and the gas valve
closes (the heater shuts down for safety and sends a failure report).
- If during the ignition attempt (max. 30 sec.) a flame appears and creates an
ionization current ≥ 0.8μA, the ignition stops and the unit remains in
operation.
Reset after safety shutdown
The heater needs to be disconnected for at least 5 sec. Afterwards repeat
ignition as described above.
Reigniting
If a malfunction occurs during operation, the igniter will automatically turn
on for a maximum duration of 30 sec. If no ionization current is recognized
within this ignition attempt period, the heater goes into safety shutdown.

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Goch GmbH & Co. KG
c) Checking Nozzle Pressure
Connect pressure measuring device to nozzle test nipple (see Combination Valve –
Top View)
Turn on heater
Compare measured nozzle pressure to rating plate specifications. If necessary,
use pressure regulator to correct.
6. Two-stage Heater Startup
For the two-stage VARIOMAX, the power control is not performed through
conventional pressure level changing. It is performed by means of a double nozzle
with High-low valve which allows two-stage regulation under constant gas pressure.
The input load is controlled by changing nozzle orifice size. The input load is
controlled by changing nozzle orifice size. At full load, the two nozzle orifices are
open. At half load, an electrically operated rod closes one of the orifices. In this
position the heater receives only 50% of the nominal input load.
a) Open the manual gas valve and measure the gas supply line pressure at the test
socket (see Combination Valve –Top View). The connected gas supply pressure
must comply with the specifications in Ch. 3 “Energy Supply”, otherwise the startup
must be interrupted.
Perform leak test at the ball valve and the screw connection up to the gas hose.
In case of appropriate gas supply pressure, the heater may be turned on using the
respective switching system (either switchbox or switching- and control system).
Measure the gas supply pressure again during full load operation. If the
gas pressure is too low, the operation must be interrupted. After
measurement, close gas pressure test socket.
b) Operating Sequence of the SG 300 Controller and Two-Stage Operation
Connect electricity to unit.
The voltage applied to the solenoid valve turns the heater on at full load.
The heater switches on correctly only at full load.
Two-stage Heater

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Goch GmbH & Co. KG
1.5 sec after switching on, the igniter creates a high-voltage spark and,
simultaneously, the solenoid gas valve opens.
- If after an ignition attempt of max. 30 sec. no flame is recognized by the
ionization flame monitoring module, the ignition stops and the gas valve closes
(the heater shuts down for safety and sends a failure report).
- If during the ignition attempt (max. 30 sec.) a flame appears and creates an
ionization current ≥ 0.8μA, the ignition stops and the unit remains in operation.
Reset after safety shutdown
- The heater needs to be disconnected for at least 5 sec. Afterwards repeat
ignition as described above.
Reigniting
- If a malfunction occurs during operation, the igniter will turn on for a maximum
duration of 30 sec. If no ionization current is recognized within this ignition
attempt period, the heater goes into safety shutdown.
c) Checking Nozzle Pressure
Connect pressure measuring device to nozzle test nipple (see Combination
Valve –Top View)
Switch heater on at full load
Compare measured nozzle pressure to rating plate specifications. If necessary,
use pressure regulator to correct. For correct nozzle pressures refer to Table in
Ch. 13.
d) Testing Two-Stage Operation
Switch on heater at full load and allow 10 to 15 min. to burn until the ceramic tiles
glow brightly.
Switch heater to half load and allow 10 to 15 min to burn. The ceramic tiles will
turn considerably darker.
Switch back to full load.

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Goch GmbH & Co. KG
7. Troubleshooting
Symptom
Possible cause
No spark, no ignition.
No power to control unit
Controller defective
Spark electrode defective
Ignition wire defective or loose
Heater sparks but will not light.
No gas supply
Combination valve will not open
Check nozzle pressure
Nozzle is dirty or clogged
Just in case of two-stage heaters:
High-low valve is stuck
High.low solenoid defective
Heater lights but locks out after
about 30 sec.
Reverse polarity on electric supply
Fame monitoring sensor (ionization
electrode) defective
Flame sensor wire defective or loose
Control unit defective
Heater lights for several minutes but
then shuts down. After repeated
ignition it remains in operation.
Fame monitoring sensor (ionization
electrode) damaged
Heater back-fires.
Ceramic tiles damaged
Sealing of the ceramic tile to the burner
body damaged

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Goch GmbH & Co. KG
8. Service and Maintenance
Warning
Before servicing and maintenance make sure to close the gas valve and
cut electrical power to the heater off. The heater must be de-energized
and secured against switching on!
Infrared heaters are to be serviced at least once per year according to local codes. In
Germany, these are DIN 4756 and DVGW-Arbeitsblatt G 638/I.
To ensure a safe, economical and stable operation, the operator of the radiant
heating system should allow the performing of inspection and service by the power
utility company, by the manufacturer of the system of by approved installation
companies.
This heater must be serviced only by a trained gas service technician. Only
personnel who have been trained and understand all applicable codes should
undertake the service.
Particularly following tasks have to be completed during the inspection and
maintenance:
Cleaning
Dust the reflectors and combustion chamber and remove encrustations. Clean the
ceramic tiles with dry air blower (do not use compressed air). Remove dirt from the
electrode assembly.
Inspection
Following settings and components must be inspected:
Check and correct nozzle pressure
Check even distribution of load on the ceramic tiles
Check quality of combustion - according to German standards: the max. CO
content in flue gas is 1000 ppm. Comply with local standards!
Check tiles for cracks
Check radiation mesh and mesh support strip for wear
Check electrodes for correct position or wear
Check condition of combustion chamber and reflectors
Check condition of mounting kit
Check electrical connections
Check all gas-carrying components (from ball valve gas connector to nozzle)
Check operation of control system, switchbox
Eventual Defects
The operator must be informed of any found defect and of the necessity of corrective
maintenance and/or part replacements that must be done.

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Goch GmbH & Co. KG
Maintenance of the actuators and flame monitoring modules as well as of other
safety devices may only be performed by the manufacturer or by his representative.
However, the appointed service technician is allowed to replace entire components
or assemblies with appropriate parts.
The operator is recommended to sign a service contract in order to make sure a
yearly maintenance of the heating installation is performed.
At the end of a service and maintenance intervention, the entire installation
must be switched on to confirm the correct operation of the heaters.
9. Changeover to different gas type
Before servicing and maintenance make sure to close the gas valve
and cut electrical power to the heater off. The heater must be de-
energized and secured against switching on!
The changeover will be performed in the following steps:
For new nozzle orifice, new air plate and new nozzle pressures see Ch. 13
Use open-end wrench size 24 and box-end wrench size 30 to unscrew nozzle
piece (2).
Insert and fix new nozzle piece.
Unscrew the 4 hexagonal screws M8 from the nozzle housing (4).
Change air plate (5) (embossing to the outside)
Fix nozzle housing again.
Turn on gas and power.
Adjust nozzle pressure accordingly.
Close test nipple.
Perform leak-test.
Change the rating plate according to the current settings.
1
3
2
4
1
5

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Goch GmbH & Co. KG
10. Setting Nozzle Pressure for One- and Two-Stage Heaters
Switch heater on at full load.
Open nozzle test nipple and connect measuring device.
Open pressure regulator cap.
Turn right –increase pressure / turn left –decrease pressure.
Set correct nozzle pressure.
Close pressure regulator cap.
Close test nipple.
Combination Valve –Top View
Gas Supply Pressure
Test Nipple
Nozzle Pressure
Test Nipple
Cap
Pressure
Regulator
Flow direction

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Goch GmbH & Co. KG
11. Minimum Mounting Height
The minimum heater to ground clearance is 2.5 m. The higher the nominal input load
of the heater, the larger need to be the distances to the ground. Applicable local
codes and standards regarding minimum mounting height are to be complied with.
According to the German DVGW-Arbeitsblatt 638 Part 1, it is not allowed to expose
people to unreasonable amounts of heat. This requirement is considered complied
with when the following minimum mounting heights are respected.
Heater Type
Recommended mounting height
VARIOMAX 6
≥2.5 m
VARIOMAX 12
≥2.8 m

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Goch GmbH & Co. KG
346 Maß B 625
Maß A
263
12. Minimum Clearance to Combustibles
In Germany, the distances between heater and combustible materials (situated in
directly as well as in indirectly radiated areas) must be large enough to ensure that
the surfaces under the heater do not get hotter than 85°C. The allowed distances to
combustibles are regulated in Germany in the DVGW 638 Part 1.
Applicable local codes and standards regarding minimum clearance to combustibles
are to be complied with.
Should you have any questions or special requirements please contact GoGaS (see
cover page).
Minimum Clearance to Combustibles in Radiated Areas
1250mm
350mm
200mm
50mm

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13. Nozzle Pressures Table (Manifold pressures)
VARIOMAX One- or Two Stage High Intensity Heater
Type
Nominal
Input
Load
Gas Type
Min. Supply
System
Pressure
Manifold
Pressure
Nozzle
Orifice ø
Air Plate ø
kW
mbar
mbar
mm
mm
VARIOMAX 06
3 - 6
Nat. gas G20
20
19,0
2 x 1,30
without
VARIOMAX 12
6 - 12
Nat. gas G20
20
18,8
2 x 1,85
38
VARIOMAX 06
3 - 6
Nat. gas G25
20
19,0
2 x 1,45
25
VARIOMAX 12
6 - 12
Nat. gas G25
20
18,6
2 x 2,00
35
VARIOMAX 06
3 - 6
Propane G31
60
50
2 x 0,80
22
VARIOMAX 12
6 - 12
Propane G31
60
50
2 x 1,10
35
14. Technical Data
Type
Gas Consumption (Half Load - Full Load)
Dimensions
G20
G25
G31
A
B
Wt.
m³/h
m³/h
kg/h
mm
mm
kg
VARIOMAX 06
0,30 - 0,60
0,35 - 0,70
0,23 - 0,47
1408
438
7
VARIOMAX 12
0,60 - 1,20
0,70 - 1,40
0,47 - 0,93
1778
807
17,5
Nat. Gas G20 ;
Hi = 9,97 kWh/m³ ;
Ws = 14,89 kWh/m³
Nat. Gas G25 ;
Hi = 8,57 kWh/m³ ;
Ws = 12,15 kWh/m³
Propane G31 ;
Hi = 12,87 kWh/kg ;
Ws = 22,55 kWh/m³
Lower Heating Value Hi und Wobbe Index Ws bei 0° C und 1013 mbar
346 B 625
A
263

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rot oder schwarz; dick
schwarz
Ionisationskabel
Zündkabel
Erdkabel
grün / gelb
Kombi- Elektrodenblock
Anschlusskabel
rot oder schwarz; dick
schwarz
Ionisationskabel
Zündkabel
Erdkabel
grün / gelb
Kombi- Elektrodenblock
Anschlusskabel
Hi-Low
15. Illustration: Connection of the Control Unit
Solenoid Valve
Solenoid Valve
SR 3010-1 (One Stage Layout)
SR 3010-2 (Two Stage Layout)
Connecting cable
Ground lead, green/yellow
Ionisation wire, black (flame sensor)
Ignition wire, red or black, thick
Electrode assembly
Connecting cable
Ground lead, green/yellow
Ionisation wire, black (flame sensor)
Ignition wire, red or black, thick
Electrode assembly