Trotec Ids 80 User manual

IDS 45 / 80

ENOPERATION MANUALOIL HEATER

TRT-BA-IDS-45-80-HS-002-INT

Operating manual – IDS 45 / 80

EN B-1

Table of Contents

1. Notes on how to use the manual.............................................A-1Legend ......................................A-12. Scope of delivery ....................................................................A-13. Guarantee provisions ..............................................................A-14. General safety instructions .....................................................A-25. Function and product characteristics ......................................A-26. Technical data ........................................................................A-2Fuels ........................................A-37. Proper and improper use ........................................................A-3Proper use ....................................A-3Improper use ..................................A-38. Installation conditions .............................................................A-39. Description of device ..............................................................A-3Oil heating unit ................................A-3Control panel ..................................A-310. Installation and commissioning ...............................................A-411. Exhaust system ......................................................................A-4Chimney duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4Wall duct .....................................A-412. Functions and operation .........................................................A-4Switching on the oil heating unit ...................A-4Switching off the oil heating unit ...................A-5Resuming operation after a failure .................A-5Safety equipment ...............................A-513. Transport ................................................................................A-514. Care and maintenance ............................................................A-6Cleaning after every 50 operating hours .............A-6Cleaning the oil heating unit .......................A-615. Disposal .................................................................................A-6Oil heating unit ................................A-6Heating oil ....................................A-6Packaging ....................................A-616. Service and repair ..................................................................A-617. Troubleshooting ......................................................................A-618.Appendix ................................................................................A-9A-9A-10Circuit diagram IDS 45. .......................... Circuit diagram IDS 80. ......................... Setting of the air setting ring .....................A-111. Notes on how to use the manual

This operating manual contains all important information required for a safe commissioning and use of your oil heating unit.It provides you with support for operating the device and remedying pos-sible problems as well as with information on disposal and customer service.Please read this manual thoroughly and completely before using the oil heating unit for the first time. Please store this operating manual and keep it within reach in order to consult it if necessary. Please observe all safety instructions and information on use and main-tenance contained in this manual. This manual should be attached to the device if the latter is made avail-able to other persons for use.Legend WARNING SYMBOL. This symbol is followed by a hazard warning which contains instructions whose non-compliance may cause serious injuries and/or death and/or property damage. Additional information which might be helpful when using the device. 2. Scope of delivery

The scope of delivery of the oil heating unit includes: 10 Wheel 2x11 Wheel cover 2x12 Snap ring 2x13 Hexagon nut 4x

14 Hexagon screw 4x15 Screw 4x16 Outlet cone17 Assembly tools1 Operating manual 2 Assembly instruction manual 3 Oil heating unit IDS 45 or IDS 80 4 Chimney connection 150 mm 5 Handle 6 Support 7 Hexagon nut 4x 8 Hexagon screw 4x 9 Support bracket for axis3. Guarantee provisions

The warranty period granted for the oil heating unit IDS 45 and/or IDS 80 shall be 12 months. Any damage to the device resulting from non-compliance with the in-structions contained in this manual shall be excluded from the guarantee. The manufacturer shall assume no liability for damages to the device and/or its accessories that are caused by unauthorised modifications.For any further terms of guarantee, please refer to the General Terms and Conditions (GTC), which are available on our website: www.trotec.de.

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4. General safety instructions

Please observe the following safety instructions! Any non-compliance with these instructions may have serious consequences for the health of per-sons and could result in property damage and damage to the environment. Risk of explosion!

• Do not operate the device in potentially flammable or explosiveenvironments. Do not install it in such environments, either.• Do not place the device on a flammable surface.• Remove any inflammable materials and chemicals from the im-mediate operating environment.Functional impairment of and damage to the device!

• Do not use the device outdoors.• Install the device in a stable position.• Keep the intake and exhaust openings free.• Do not cover the device during operation.• Only disconnect the device from the mains once it has cooleddown completely.• Do not use any chemicals for cleaning the device.Risk of injury and damage to property due to defective devices!

• Before each use of the device, check its accessories and connec-tion parts for possible damages. Do not use any defective devicesor device parts. • Do not use the device if you detect any damage to its plug andcables. Defective power cables represent a serious health threat.Danger to life through electrical shock!

• Only connect the device to power sources that are in good tech-nical order. Do not use damaged wall outlets!• Pull the connection cable out of the wall outlet by pulling it atits plug. • Do not touch electrical connection cables when your hands arewet!• Protect the electrical connection cables against damage causedby, for example, animals.• Do not carry out any changes or repairs on the device!• Do not expose the device to any liquids. • Do not apply any liquids to the interior of the device. If this doeshappen nevertheless, pull out the power cord and have the de-vice checked by a specialist workshop. Risk of injury!

• Do not insert any objects into the intake and exhaust opening ofthe device.• Do not reach into the existing openings.• Do not leave children or animals unattended near the operatingdevice!• Do not operate the device in rooms with insufficient supply ofcombustion air.• Avoid the improper use of fuels.Risk of environmental pollution!

• Do not let any leaked fuel seep away into the soil and prevent itfrom entering the sewer system.5. Function and product characteristics

The oil heating unit IDS 45 and/or IDS 80 is used to heat up room air in order to achieve a fast heating of large rooms. The oil heating unit is operated with heating oil. The device features an indirect combustion and is provided with an exhaust connection in order to discharge the exhaust gas via the chimney.A selection of two operating modes ensures that the oil heating unit can be controlled both manually by the user as well as automatically with the support of the thermostat.6. Technical data Type IDS 45Type IDS 80ParameterValueValueArticle number1.430.000.1301.430.000.135Electrical connection230 V 230 VFrequency50 Hz 50 HzNominal current max.3.8 A 6.4 APower consumption850 W 1140 WAir volume2500 m³/h 4350 m³/hFanAxial fanAxial fanNominal heat load max.59 kW91 kWNominal heat output52.5 kW80.2 kWTemperature increase ΔT 1)66 °C77 °COil consumption max.5.59 l/h8.64 l/hTank capacity65 l105 lAir transportation hose connection 2)1 x ø 350 mm1 x ø 400 mmAir transportation hose connection 2)2 x ø 300 mm2 x ø 300 mmChimney connectionø 150 mmø 150 mmThermostat connectionseriesseriesCombustionindirectindirectNozzle1.10-80° W (gal/h)1.50-80° W (gal/h)Sound pressure level (at distance of 1 m)72 dB (A)75 dB (A)Length1435 mm1740 mmWidth555 mm690 mmHeight940 mm1025 mmWeight 80 kg110 kg1) indicates the temperature increase. ΔT + ambient temperature = exhaust air temperature2) optional

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Fuels

The following fuels have been approved for use with the oil heating unit IDS 45 and/or IDS 80: heating oil EL, diesel7. Proper and improper use

Proper use

The oil heating unit IDS 45 and/or IDS 80 has been developed for the gen-eration of hot air and may be used indoors and in roofed outdoor areas.The device can be used for heating large rooms such as storerooms, workshops, building sites, greenhouses or cowsheds. It has been de-signed for stationary operation without frequently changing locations. The oil heating unit IDS 45 and/or IDS 80 can be used in conjunction with air transportation hoses.Any application deviating from the above-mentioned use is deemed in-admissible! Improper use

The device may not be installed or operated in potentially inflammable and explosive rooms or areas. The device may not be used in rooms with an insufficient supply of com-bustion air. 8. Installation conditions

When choosing the installation location of the oil heating unit, a number of spatial and technical conditions must be taken into account. Any non-compliance may impair the functioning of the device and/or of the acces-sories or result in hazardous situations for people and property.The following points are to be observed during installation: • The device may be operated indoors and in roofed outdoor areas.• The device must be installed in a stable position and placed ona fireproof surface.• The device must be installed near a chimney or external wall.• The device must be connected to a properly secured mainssocket.• The installation room of the device must be sufficiently ventilated.• The minimum distance of the intake opening of the device to thewall must be at least 1 m (see figure).• The minimum distance of the device to inflammable materialsmust be at least 2 m.• The intake and exhaust openings must not be covered.• There may be no walls or large objects near the device.• A sufficient number of fire-extinguishing systems must be avail-able.9. Description of device

The oil heating unit IDS 45 and/or IDS 80 consists of the following com-ponents: Oil heating unit

1 Combustion chamber 8 Heating oil filter2 Burner 9 Heating oil circuit 3 Nozzle 10 Support and handle 4 Solenoid valve 11 Wheel 5 Pump 12 Tank6 Motor 13 Exhaust opening7 FanControl panel

1 Reset button with indicator lamp 4 Lamp2 Selector switch 5 Power supply cable (continuous operation/thermostat operation)3 Thermostat socket

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10. Installation and commissioning

• Check that the scope of delivery of your oil heating unit is com-plete. If an accessory part is missing, please contact the Troteccustomer service or the specialist dealer from whom you pur-chased the device.• Check the oil heating unit and its connection parts for possibledamages.• Mount the support, the handle, the wheels and the outlet coneto the oil heating unit. Please refer to the supplied assembly in-struction manual for further information. Please use the suppliedassembly tools.• Make sure to comply with the requirements described in thechapter "Installation conditions". • Correctly connect the exhaust system of the device to a chimneyor an external wall as shown in the chapter "Exhaust system".• Fill the heating oil into the tank with the device switched off andcooled down.• Inspect the device prior to commissioning and check it regularlyfor its proper condition during operation.• Make sure that the characteristics of the mains supply corre-spond to those indicated on the rating plate.• Each time before switching on the device, make sure that the fancan move freely before plugging the power plug into the mainssocket.• Connect the power supply cable to a properly secured mainssocket (230 V / 50 Hz / 10 A). On construction sites, a residualcurrent circuit breaker must be connected upstream of the mainssocket according to VDE 0100/0105.The oil heating unit is now ready for operation. Use the device according to the functions described in chapter 12 "Functions and operation". 11. Exhaust system

• Before planning the installation of the exhaust system, the localchimney sweep must be informed according to DIN 18160.Risk of injury due to intoxication!

Improper installation of the exhaust system may cause health problems.Have the installation carried out by a specialised crafts-man! • Make sure that an unobstructed and sufficient supply of combus-tion air (e. g. by means of ventilation openings in doors, ceilings, windows, walls or an ambient air network) is provided.•Have the exhaust gas values of the burner checked regularly.Chimney duct

Wall duct

A min. 1 m 1 Chimney connectionB min. 1 m 2 Wall duct with pipe elbow min. 5° C as short as possible 3 Chimney - minimum internal dimensions 20x20 cm D ≥ ø 150 mm 4 Opening for cleaning with explosion E min. 1 m protection cap5 External wall6 Draft reinforcement, H-shaped12. Functions and operation

The device may only be used by persons who have been trained in op-erating the device.Switching on the oil heating unit

The oil heating unit features two operating modes:1. Manual modeThe generator can operate in manual mode.

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• Switch the device on by setting the selector switch to the position"ON" (continuous operation). 2. Automatic modeThe oil heating unit can only operate in automatic mode if a control device (optional) is connected to it, e.g. a thermostat. The thermostat is to be connected to the thermostat socket.• Switch the device on by setting the selector switch to the position"ON" + " (thermostat operation). If the start-up cycle has been completed, the electronic control unit will confirm that the start-up of the device is complete by activating a red flashing light on the reset button.Switching off the oil heating unit

• Switch the device off by setting the selector switch to the posi-tion "0".• If you are using a thermostat, switch the device off via the set-tings of the control device (e.g. by setting the thermostat to a lowtemperature).The flame is extinguished and the fan will continue running for approx. 90 seconds in order to cool down the burner.Damage to the device due to overheating!

Do not switch off the device by pulling out the power cord. This may cause the device to overheat.Switch the device off properly. Only disconnect the power plug if the fan motor has come to a complete standstill.• Wait until the automatic aftercooling has been completed.• Secure the device against being accidentally switched on againby pulling out the power cord.Resuming operation after a failure

During the initial commissioning of the device or after the heating oil circuit has been completely emptied, the inflow of heating oil to the noz-zle may be insufficient. This will cause the flame control system to be activated and the device will be blocked.• Wait for approx. 1 minute.• Press and hold the reset button for at least 5 seconds.• Switch on the device.If the device is still not starting up:• Make sure that there is enough heating oil in the tank.• Press the reset button.In order to determine the cause of the fault:• see the chapters "Safety equipment" and "Troubleshooting"Safety equipment

The oil heating unit features an electronic flame and maximum tem-perature monitoring system that uses a photoelectric cell and a safety thermostat.The electronic control unit controls the start-up, shutdown and safety shutdown times in the event of malfunctions. The control unit is equipped with a reset button whose colour (operation indicator) is depending on the operating mode:• switched off if the device is in pause or standby mode and ex-pecting the heating demand• continuous green light for normal operation of the device• continuous red light for safety shutdown of the device• flashing orange light if the operation is interrupted due to consid-erable mains fluctuations (T < 175 V or T > 265 V); the operationis automatically resumed if the voltage has stabilised in the rangeof 190 V to 250 VIf the device has triggered the safety shutdown:• Press and hold down the reset button for 3 seconds in order toresume operation.Risk of injury due to deflagration!

Unburned heating oil may accumulate in the combustion chamber and can be ignited when the device is switched on the next time.Do not restart the device two times in a row.If the safety shutdown is still activated:• Determine and remove the cause of the fault before commission-ing the oil heating unit again (see chapter "Troubleshooting"). • Press and hold the reset button for at least 5 seconds. The self-diagnostic programme will start. Once the programme has been completed, the reset button will light up in the colour (self-diagnostic indicator) depending on the cause of the fault:• flashing orange light if an incorrect flame has been detected dur-ing start-up• flashing red light if a missing flame has been detected duringstart-up• flashing red/green light if a missing flame has been detected dur-ing operation• continuous orange light if an internal error of the electronic con-trol device has occurredIn order to determine the cause of the fault:• see chapter "Troubleshooting"13. Transport

• Switch the device off as described in the chapter "Functions andoperation".• Wait until the device has cooled down completely.• Before transporting or adjusting the device, check if the tank capis tightly closed.Risk of environmental pollution!

Heating oil may leak during transport or handling of the device. The filling plug of the tank cap does not guaran-tee tightness in order to allow air to be introduced and the tank to be emptied during operation.Only transport or shift the device with the tank cap tightly closed.

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14. Care and maintenance

In order to ensure a trouble-free operation of the device, the combustion chamber, the burner and the fan are to be cleaned regularly.• Switch the device off as described in the chapter "Functions andoperation".• Wait until the device has cooled down completely.Cleaning after every 50 operating hours

• Dismount the heating oil filter. Remove the filter insert and cleanit using clean heating oil.• Dismount the upper housing part and clean the inner part as wellas the fan blades using a cleaning fleece and a brass brush if itis heavily soiled.• Check the condition of all cables and high-voltage connections.• Dismount the burner and clean its components using a brassbrush.• Clean the electrodes. Check the distance of the electrodes andadjust it if required (see figure).• Have the combustion chamber cleaned by the customer service.• Mount the components in the reverse order.Cleaning the oil heating unit

• Wipe the exterior of the device using a wet cloth. The paintedand plastic surfaces may not be scoured. Do not use any solvent-based cleaning agents.15. Disposal

The heating oil must be drained from the tank of the oil heating unit and collected.Oil heating unit

Electronic equipment may not be disposed of in the domestic waste, but must be correctly disposed of in accordance with the EUROPEAN PARLIA-MENT directive 2002/96/EC of 27th January 2003 regarding used electri-cal and electronic equipment. Please dispose of this device according to the applicable legal regulations after its final decommissioning.Heating oil

Fuels must be disposed of according to the local regulations.Packaging

The packaging of the oil heating unit consists of cardboard/paper and plastic. The materials must be disposed of in the designated containers according to the local regulations or at a recycling depot. 16. Service and repair

Before contacting our customer service in order to solve an existing tech-nical problem, please try removing the error by following the instructions described in the chapter "Troubleshooting".If you have any further questions regarding the functioning and operation of the oil cleaning unit or if you wish to receive further information in the event of a claim or with regard to guarantee aspects, please do not hesitate to contact us at any time. Please contact: Trotec GmbH Co KG Grebbener Straße 7D-52525 HeinsbergTel.: 49 (0) 2452 / 962 - 400Fax.: 49 (0) 2452 / 962 - 200Email: [email protected]www.trotec.de.17. Troubleshooting

Danger to life due to improper repair!

Do no attempt to carry out modifications or repairs on the device. Any unauthorised modification may result in serious injuries or even death. Have repairs carried out by a certified specialist workshop.

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ProblemReset buttonCauseError correctionOperation indi-catorSelf-diagnostic indicatorFan does not start run-ning and flame is not ignitedswitched off-Control device is incor-rectly set- Check if the control equipment is correctly set(e.g. the temperature set at the thermostat mustbe higher than the room temperature).Control device defective- Have the control device replaced by the customerservice.Fan does not start run-ning or switches off dur-ing start-up or operationflashing orange light-no power supply- Check the characteristics of the electrical system(230 V -1~ - 50 Hz).- Check the function and position of the selectorswitch.- Check if the fuse is intact.Voltage < 175 V- Check the supply voltage. The device will auto-matically restart if the voltage exceeds 190 V.Voltage > 265 V- Check the supply voltage. The device will auto-matically restart if the voltage falls below 250 V.Fan switches off during start-up or operationcontinuous red lightflashing orange lightFlame is present prior to the ignition of the trans-former- Contact the customer service and have the devicecleaned and heating oil residues removed fromthe combustion chamber.Photoelectric cell defective- Have the photoelectric cell replaced by the cus-tomer service.flashing red light or flashing red/green lightMotor winding interrupted or blown- Have the motor replaced by the customer service.Motor bearing blocked- Have the motor bearing replaced by the customerservice. Motor capacitor blown- Have the motor capacitor replaced by the cus-tomer service.no ignition- Check the connections of the ignition cables to theelectrodes and the transformer.- Check the position and the distance of the elec-trodes.- Check if the electrodes are clean.- Have the transformer replaced by the customerservice.Flame control system de-fective- Have the flame control equipment replaced by thecustomer service.Photoelectric cell defective- Have the photoelectric cell cleaned or replaced bythe customer service.Burner is not or only in-sufficiently supplied with heating oilContact the customer service in order to:- have the integrity of the coupling between thepump and motor checked.- have the heating oil circuit checked for air thatmay have entered the circuit and to have the tight-ness of the lines and filter seal checked.- have the nozzle cleaned or replaced.

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ProblemReset buttonCauseError correctionOperation indi-catorSelf-diagnostic indicatorSolenoid valve defectiveContact the customer service in order to:- have the electrical connections checked.- have the safety thermostat LI checked.- have the solenoid valve cleaned or replaced.continuous or-ange lightInternal error of the elec-tronic control unitContact the customer service in order to:- have the control unit reset; try to start up the de-vice at least twice. If the fault still occurs after-wards, replace the control unit.Fan starts running and flame burns with smoke formationcontinuous green light-insufficient supply of com-bustion air- Remove all obstacles or blockages from the intakeand/or exhaust openings.- Have the position of the air setting ring checked bythe customer service.- Have the support disc of the burner cleaned by thecustomer serviceSupply of combustion air too high- Have the position of the air setting ring checked bythe customer service.used heating oil contami-nated and/or containing water- Replace used heating oil with clean heating oil.- Clean the heating oil filter.air has entered the heating oil circuit- Have the tightness of the lines and heating oil filterchecked by the customer serviceinsufficient heating oil quantity at the burnerContact the customer service in order to:- have the pump pressure value checked.- have the nozzle cleaned or replaced.too much heating oil at the burnerContact the customer service in order to:- have the pump pressure value checked.- have the nozzle replaced.Device does not switch offcontinuous green light-Solenoid valve seal defec-tive- Have the solenoid valve replaced by the customerservice.

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18. Appendix

Circuit diagram IDS45

AP Control unit FO Photoelectric cellTA Thermostat connection CO Capacitor ST Indicator lamp MV Fan motor LI 1 Safety thermostat FUA Fuse EV 1 Solenoid valve FU FuseRE Relay RV Selector switchLF RFI filter IT Ignition transformerRF Heated filter (optional)