Hydor HCBI50 User manual

HREI Inst Issue 1: 09.05.16
Installation and Maintenance Instructions.
THESE INSTRUCTIONS MUST BE READ FULLY BEFORE COMMENCING INSTALLATION.
Owner / installer: The life of this apparatus and its eciency will be increased if
its use and maintenance is carried out in accordance with these instructions and
current statutory requirements. The installation and initial adjustments should be
carried out by a qualified and competent technician. Hydor Limited should be
consulted before submitting or fitting parts from another manufacturer. It is the
responsibility of the installer to verify that the installation is in accordance with
the following standards and the owner is given the current User’s Manual.
Any modifications to the unit or its installation, even the smallest
modification, change or elimination of security components or pieces that
influence the eciency or loss of ventilation, will result in the CE Certification
and Hydor’s warranty being cancelled.
1. General
1.1 It is important these Installation and Maintenance Instructions are fully
adhered to.
1.2 Full details of the unit supplied are shown on the product nameplate. If in
doubt about any detail contact Hydor or its agents for clarification.
1.3 All electrical installation must be carried out by a suitably qualified
and competent personnel in accordance with all current statutory
requirements.
1.4 These instructions cover only the Hydor product and do not include the
supply or installation of safety equipment that may be required, e.g.
adequate protection and proper electrical isolation.
1.5 Any declarations made by Hydor about product installation and safety,
are dependent on other equipment being used within installation which
themselves meet the requirements of the Standards and Directives or your
region.
1.6 The heater is designed for use in an ambient temperature of up to
50C and up to 90% relative humidity. The unit is NOT suitable for corrosive
or explosive atmospheres.
HCBI Indirect Gas Fired Heater
incorrect
correct, minimum height 5mm

HREI Inst Issue 1: 09.05.16
1.7 The installer should provide easy access to the brooder to facilitate future
maintenance.
1.8 The installer should ensure the brooder is adequately supportedor
suspended .
1.9 This product is not intended for use by young children or infirm persons
unless they have been adequately supervised by a responsible person
to ensure that they can use the product safely. Young children should be
supervised to ensure that they do not play with the appliance.
WARNING The heater must be isolated from both the gas and power
supply during installation and maintenance. The fan must be earthed in
accordance with the local regulations.
2. Technical Characteristics
2.1 CBI Model. The HCBI heaters are equipped with
an axial fan. They are designed for direct
blowing into the room. They can be
suspended or equipped with supports for
installation on the floor.
2.2 Performance of CBI gas unit heater
Code Throw
Gas Flow
Natural G20
20 mbar
(m³/h)
Groningen G25
25 mbar
(m³/h)
Propane 31
37 mbar
( kg/h)
HCBI50 30 5.29 5.88 3.91
HCBI76 35 8.04 8.94 5.93
HCBI98 40 10.58 11.76 7.81
Code
Calorific
Output
(kW)
Usable
power
(kW)
Eciency
(%)
Fan
(mm)
Speed
(r/min)
Air flow
(m³/h)
Delta T°
of the
air
(°C)
HCBI50 50 46 92 500 1350 4500 30
HCBI76 76 70 92 600 1350 6600 31.2
HCBI98 98 90.2 92 2 x 500 1380 9000 29.5

HREI Inst Issue 1: 09.05.16
Code
Smoke Exhaust
Diameter
(mm)
Air Inlet
Diameter
(mm)
Supply
Voltage
HCBI50 100 100
Single-phase 230 Volts / 50
Hz - IP54
HCBI76 130 130
HCBI98 130 130
Code
Electrical
Power
(W)
Electrical
Current
(A)
Operating
Temperature
(°C)
Weight
(kg)
HCBI50 470 2.1 0/+40 140
HCBI76 760 3.4 0/+40 200
HCBI98 890 40/+40 225
2.3 Dimensions
E
F
B
A
C D
G
Code A B C D E F G Weight
(kg)
HCBI 50 1791 638 617 1026 130 130 3/4’’ 140
HCBI 76 1791 892 617 1026 130 130 3/4’’ 200
HCBI 100 1791 1146 617 1026 130 130 3/4’’ 225

HREI Inst Issue 1: 09.05.16
2.3 The installer should ensure the heater is adequately supported or
suspended. Please refer to the following pages taking particular attention
regarding the dimension and weights.
2.4 This product is not intended for use by young children or infirm persons
unless they have been adequately supervised by a responsible person
to ensure that they can use the product safely. Young children should be
supervised to ensure that they do not play with the appliance.
WARNING The heater must be isolated from both the gas and the
power supply during installation and maintenance. The heater must be
earthed in accordance with the local regulations.
3. Installation
3.1 Upon receipt, the gas unit heater is delivered on a wooden pallet, plastic
film and cardboard packaging. This should be carefully removed and the
heater should be visually inspected to check for any damage. The unit is
normally supplied as a complete unit with accessories.
3.2 If there are any queries concerning the equipment,Hydor should be
contacted prior to the installation.
3.3 The HCBI heaters can be installed suspended from secure fixings or
supported on a suitable frame, fixed to the floor. They are designed to
blow directly into the room and are equipped with an axial fan.
3.4 Ensure there is free space around the heater and for ecient and safe
operation the following minimum distances must be adhered to:
3.4.1 A minimum space of 600mm above the fan intake.
3.4.2 A minimum space of 500mm around the heater.
3.4.3 A minimum distance of 1000mm above the floor.
3.4.4 Ensure there is sucient space behind the heater, to open the
burner door, of at least 900mm.
3.5 For a good functioning and the security of the device, it's necessary to
respect the minimum installation spaces here below:
3.5.1 Foresee a minimum space of 0,6 m above the unit (fan side).
3.5.2 Foresee sucient clearance for the opening of the burner door.
3.5.3 The heater must be installed at minimum 1 m from the floor.
3.5.4 No object can be placed at less than 0,5 m around the heater..

HREI Inst Issue 1: 09.05.16
0,6 m
6 m mini
1 m mini
0,9 m mini
0,5 m
0,5 m
3.6 Suspended mounting: before mounting the device, it is necessary to
make sure of the support’s strength. The unit is equipped with 4 MS
threaded inserts on the top, to can be suspended. It is necessary to used
slings or threaded rods adapted to the weight of the unit. The mounting
must be perfectly aligned, as shown on the drawing here below.
Be careful, make sure to always use lock nuts to ensure the fastening.

HREI Inst Issue 1: 09.05.16
3.7 If the heater is to be suspended, it is necessary to make sure of the
support's strength. The heater is equipped with 4 - M8 threaded inserts
on the top of the unit. Ensure the slings or suspension rods are suitable
to take the weight of the heater model safely. These moutings must be
perfectly aligned with the unit, as per following drawing:
Present 4 feet and secure with screws M8.
3.7 If the heater is to be placed on feet, refer to the drawing below:
WARNING Support must be perfectly level, check the horizonal level
of the heater. Attach the feet to the ground to prevent it from being
moved unintentionally.

HREI Inst Issue 1: 09.05.16
4. Electrical Connection and Control Regulation
4.1 The power supply is single-phase 230V/50Hz with a protected
electrical cable (1). The section of the cable and its protection must be
sized according to the number of units on the line and its length.
The regulation box will be connected to the gas heaters by a pilot wire.
Connect the regulator to the first heater, then connect the first heater to
second and proceed in the same for the others until the last one.
For people and equipment safety, it is recommended to install a switch
isolator (2). The connection must be realized by a qualified installer
following the diagram above.
Refer to the technical manual given with the regulation.
WARNING Be sure that general power supply is cut o before any
operation on the line. Electrocution hazard.
2
1

HREI Inst Issue 1: 09.05.16
4.1 All gas heaters are equipped as standard with a pilot wire card.
The control sends a signal via the pilot wire, to the units equipped with the
pilot wire receptor (RFP card), which execute the operating order.
4.2 Four types of information are transmitted:
4.2.1 Heating demand
4.2.2 Ventilation only
4.2.3 Reset
4.2.4 Stop
4.3 Regular inspection of the brooder, should be carried out to ensure it is
operating correctly.
4.4 Thermostat with remote probe: Control box with programmable
touchscreen and remote probe. This regulation can manage up to 6
heaters. The use of a remote probe allows you to install the control box
outside the managed area. This box has also a default light which is
possible to connect. However, if the thermostat is connected to several
units, it is impossible to identify the one which has a defect.
REGULATION
HEATER
Reset
Pilot wire
Live
Diode
Diode
Heating
Ventilation

HREI Inst Issue 1: 09.05.16
A: Neutral (blue)
B: Live (brown)
C: Earth (green yellow)
D: Pilot (black)
4.5 Diagram connection
E N L
A. Neutral (blue)
B. Live (brown)
C. Earth (green-yellow)
D. Pilot Wire (black)

HREI Inst Issue 1: 09.05.16
4.6 Diagram for CTM
4.6.1 Control and regulation
A. Neutral (blue)
B. Live (brown)
C. Earth (green-yellow)
D. Pilot Wire (black)
E N L

HREI Inst Issue 1: 09.05.16
4.6.2 Control, regulation and default
E N L
A. Neutral (blue)
B. Live (brown)
C. Earth (green-yellow)
D. Pilot Wire (black)
E. Default (grey)

HREI Inst Issue 1: 09.05.16
4.7 Electrical diagram
Live (brown)
Neutral (blue)
Earth (green-yellow)
Pilot (black)
Default (grey)
4.7.1 The temperature sensor of the burner modulation thermostat
(Mod) is placed on the fan’s protection grille.
VT Blowing fan
RFP Pilot wire receptor
Limit Overheat thermostat with manual reset
Fan Thermostat for fan start up
Reg Thermostat for burner regulation
Mod Thermostat for burner modulation (2 stages option)
CC Control box with isolation transformer
MVE Extractor fan
PA Burner air pressure
SI Ionization probe
EA Ignition probe
EVR Modulating gas valve (2 stage option)
EVG Gas valve

HREI Inst Issue 1: 09.05.16
WARNING In normal operation, never stop the unit by cutting the
power supply. Wait for the fan to shutdown
4.7.2 RFP Card
5 Flue Pipe Connection
5.1 Single flue kit connexion. The combustion air is taken
directly into the room and the smoke exhaust is done
to the exterior thanks to a single flue through the roof.
5.2 Mounting type B22: Flue pipe diameter: 130 mm
5.2.1 Tee with airtight
5.2.2 Two single extensions of 1 m
5.2.3 Single roof terminal
NOTE The roof outlet must be
located at least at the ridge height.
WARNING Not Suitable for
poultry houses.
NOTE Foresee a sucient
ventilation in the room.
The required fresh air for
combustion must be at least of
100m³/h /unit. The section of flue must be at least equal to the diameter
of the heater outlet. The smoke exhaust cannot be vertical or at 45°
minimum. The total length of the connection cannot exceed 6m,
knowing that: elbow 90° or 45° = 1m of flue. If the outside part of the
flue is higher than 2m, foresee an insulated pipe.
Power and regulation
connector
Fan connector
Burner resetBurner default
Burner connector
3
1
2

HREI Inst Issue 1: 09.05.16
5.3 Concentric Flue Kit Connection. The connection for combustion air intake
and smoke exhaust is made horizontally or vertically towards the outside
of the room.
WARNING The fumes condensates should not flow inside the unit,
risk of corrosion. If it is needed, foresee a condensate collector. In case
of horizontal concentric installation, foresee a slope of 2° minimum and
opposed to the unit to drain the condensate.
5.4 Mounting type C12: Flue pipe diameter: 130 mm
5.4.1 Two single elbows at 90°
5.4.2 Two single extensions of 1 m
5.4.3 Concentric wall terminal
• Condensate trap
NOTE It is possible to
extend or divert the
concentric kit with
approved accessories.
5.5 Roof type C32: Flue pipe diameter: 130 mm
5.5.1 Two single extensions
5.5.2 1 concentric roof terminal
• Condensate trap
NOTE It is possible to extend or divert the concentric kit with
approved accessories. The use of flues involves a perfect
sealing. To check the installation, it is necessary to use a
non-aggresive libricant for the gasket, example: soapy water.
NOTE The junctions must be sealed and rigid. The
section of flue must be at least equal to the diameter
of the heater outlet. The smoke exhaust cannot be
vertical or at 45° minimum. The total length of the
connection cannot exceed 6 m, knowing that:
elbow 90" or 45° = 1 m of flue. If the outside
part of the flue is higher than 2m,
foresee an insulated pipe.
321
2
1

HREI Inst Issue 1: 09.05.16
6. Gas circuit
All the following gas installation should be carried out by a technically
qualified of competent person who must have a current Gas Care
Certificate. If heater has been electrically installed make sure the unit is
isolated from the main supply.
6.1 Change of gas
The unit heaters are equipped with atmospheric gas torch burners,
permitting the use of Natural gas G20, Natural gas G25 and Propane.
The combustion ports are engineered so as to ensure very good stability
of the flame without separation or return towards the injectors.
The service visits must be carried out by a qualified professional person
Changing the gas is carried out in the following manner:
6.1.1 Disconnect the electrical supply connector and close the gas
inlet.
6.1.2 Unscrew the gas line fixing nut (Item 1) on the gas valve and
also the three screws (Item 2) which retain the injector ramp on
the burner block.
6.1.3 Change the injectors (see adjustment table).
6.1.4 Screw in the new injectors (Item 3) changing the seals (Item 4)
and making sure concerning sealing.
The injectors must be installed dry.
6.1.5 Reassemble the ramp and connect the gas line to the gas valve,
replacing the seal, make sure during assembly not to forget, or
damage the seal.
6.1.6 Check for sealing after assembly.
6.1.7 Adjust the gas ramp pressure on the regulator.
WARNING This operation must be done with the gas and electricity
supplies cut o.

HREI Inst Issue 1: 09.05.16
The adjustment of the gas pressure is made with the burner running
6.2 Adjusting the gas pressure is done in the following manner:
6.2.1 Open the valve pressure regulating protection screw.
6.2.2 Unscrew the pressure test point, connect the pressure gauge
(5)
6.2.3 Adjust the ramp pressure (6), in accordance with the adjusting
table.
6.2.4 After adjustment, do not forget to put the protective screw back
in place and to close the pressure test point.
6.2.5 Check for sealing after making the adjustment.
6.2 Adjustment table for stage 1 valve
Types CBI 50 CBI 76 CBI 98
Adjustment
for G20
Regulator
Pressure
Low Speed 4.5 4.5 4.5
High Speed 77.5 7.5
Gas ramp injectors 8 x AL 2.50 12 x AL 2.50 16 x AL 2.50
Extractor washes -35 30
Adjustment
for G25
Regulator
Pressure
Low Speed 5.5 5.5 5.5
High Speed 9.5 10 10
Gas ramp injectors 8 x AL 2.50 12 x AL 2.50 16 x AL 2.50
Extractor washes -35 30
Adjustment
for G31
Regulator
Pressure
Low Speed 13 13 13
High Speed 20 20 20
Gas ramp injectors 8 x AL 1.50 12 x AL 1.50 16 x AL 1.50
Extractor washes -35 30

HREI Inst Issue 1: 09.05.16
6.3 Adjustment table for stage 2 valve
Types CBI 50 CBI 76 CBI 98
Adjustment
for G20
Regulator Pressure 4.5 4.5 4.5
Gas ramp injectors 8 x AL 2.50 12 x AL 2.50 16 x AL 2.50
Extractor washes -35 30
Adjustment
for G25
Regulator Pressure 5.5 5.5 5.5
Gas ramp injectors 8 x AL 2.50 12 x AL 2.50 16 x AL 2.50
Extractor washes -35 30
Adjustment
for G31
Regulator Pressure 13 13 13
Gas ramp injectors 8 x AL 1.50 12 x AL 1.50 16 x AL 1.50
Extractor washes -35 30

HREI Inst Issue 1: 09.05.16
6.4 Gas connection
First of all it is necessary to check that the device is in conformity with the
type of gas distributed. For this purpose, you must refer to the indications
shown on the identification plate. The gas supply must be appropriated to
the power of the heater and be equipped with all the security and
inspection devices required by current standards. A precise study must be
carried out on the diameters of the piping depending on the type and the
flow of gas and the length of the piping. It is necessary to make sure that
pressure drops in the piping do not exceed 5 % of the supply pressure.
The gas connections must be made in conformity with the
recommendations for indoor.
WARNING before opening the gas network, check the sealing up to the
unit heater solenoid valve
Gas connection
A Over 50mbar natural gas supply
B Under 50 mbar natural gas supply
C LPG supply
Gas connection kit*:
6.4.1 Gasket (supplied)
6.4.2 Connection with air heater (supplied)
6.4.3 Gas regulator
6.4.5 Filter
6.4.5 Gas valve
*to know more about this kit, please refer to the instruction manual
supplied with connection kits.

HREI Inst Issue 1: 09.05.16
7. Commissioning
7.1 Operating principle
7.1.1 The control box tests the break contact of the air pressure
switch and turns on the smoke extractor. Its proper functioning
is controlled by the dierential air pressure switch. In case of
lack of air, it prevents the control box from following its cycle.
7.1.2 After pre-ventilation, the ignition electrode lights up and the
valve allows the gas passing through the injectors.
7.1.3 If the air/gas mixture is not ignited or is not detected by the
ionization sensor, the flame control box tries once more and
switches on safety position.
7.1.4 Once the burner is ignited, the blowing fan is triggered when
the air temperature is higher than the fan thermostat value
(35°C to 40°C).
7.1.5 In the case of a fan malfunctioning, the overheating thermostat
cuts o the burner if the temperature exceeds 90 °C.
WARNING Never stop the device before the fan has totally stopped. The
lack of cooling can necessitate to reset the overheating thermostat and
can damage the heat exchanger over the long term.
This commissioning must be carried out by a Qualified Technician with
a current Gas Care Certificate.
7.2 Initial operation
7.2.1 To commission the heater, switch on the heater and turn the
regulator to demand. The control box tests the break contact of
the air pressure switch and turns on the smoke detector. Its
function is controlled by the dierential air pressure switch. If
there is a lack of air, it prevents the control box from
commencing its cycle.
7.2.2 After pre-ventilation, the ignition electrode lights up and the
valve allows the gas to pass to the injectors.
7.2.3 If the air/gas mixture is not ignited or is not detected by the
ionization sensor, the flame control box tries once more and
if not detected again, switches to the safety position.
7.2.4 Once the burner has ignited, the main fan is triggered when the
air temperature is higher than the fan thermostat. [35°C - 40°C].
7.2.5 In the case of the main fan malfunctioning, the overheat
thermosat cuts o the burner should the temperature
exceed 90°C.

HREI Inst Issue 1: 09.05.16
WARNING Never stop the device before the fan has totally stopped
running. The lack of cooling air can cause the overheat thermostat to
trip and require resetting. This can also cause damage to the heat
exchanger over a long term.
9. Maintenance
The maintenance visits must be carried out bv a qualified professional
person.
9.1 Correct and regular use and maintenance of the unit heater allows an
ecient operation, minimum consumption , as well as a long life.
The maintenance must be done with the device cold, with the gas and
electricity supplies cut o.
9.2 Check the proper functioning of all safety devices and check that all
screws are correctly tightened
9.3 Heat exchanger, smoke extractor and venturi :
9.3.1 Unscrew and open the blowing grille and the upper access
door to clean the heat exchanger.
9.3.2 To get access to the rear of the heat exchanger bends, unscrew
the 2 metal plates on the lateral sides.
9.3.3 Clean the smoke extractor and the venturi by opening the
burner compartment door.
9.3.4 Fan: Clean it with compressed air
9.3.5 Flue pipe: Dismantle the pipe, sweep it and check leaks.
9.3.6 Body and grilles: Clean it using a duster
9.3.7 Gas burner: Dismantle the burner, check the burner ramp state
and clean it. Check the state of the ionization sensor and
ignition electrode, change it if it is necessary.
9.3.8 Gas filter: Dismantle the dirty cartridge and clean it with
compressed air.
The heaters used for poultry houses must be cleaned and maintained
more frequently. It is necessary to clean the device each time a change
is made to a new batch!