Warmco XR Series User manual

INSTRUCTION MANUAL
PREMIX UNIT AIR HEATER
TYPE XR
Production from 2019
THIS DOCUMENT MUST ABSOLUTELY BE READ BEFORE STARTING THE
INSTALLATION.
INSTRUCT USER AND LEAVE THIS DOCUMENT WITH HEATER FOR
REFERENCE.
Date: 01-02-2019
Instruction manual version XR-GB-4001-a
Heaters for GB
heaters for natural gas G20 and Propane

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 2/25
Introduction
This installation and user manual is produced specifically for the gas, electrical and mechanical
installer , it also gives instructions how to use and maintain the heater.
It is most important to follow the directions in this booklet for safe operation of this product.
1Content:
Page
1 CONTENT: 2
2 GENERAL 3
2.1 S AFETY WARNINGS 3
2.2 I MPORTANT CHECKS BEFORE INSTALLATION 3
2.3 G UARANTEE 4
3 TECHNICAL DETAILS: 5
4 INSTALLATION 7
4.1 P OSITIONING 7
4.2 G AS CONNECTION 9
4.3 E LECTRICAL CONNECTION 9
4.4 A IR INTAKE / COMBUSTION PRODUCTS DISCHARGE 10
4.5 I NSTALLATION R OOF OR W ALL TERMINAL 11
5 FUNCTIONING OF THE UNIT 14
5.1 G ENERAL 14
5.2 B URNER CYCLE 14
5.3 D ELTA -T- REGULATION ( TEMPERATURE CONTROLLED DE - STRATIFICATION FAN ) 14
5.4 S UMMER VENTILATION 14
5.5 H IGH LIMIT PROTECTION 15
5.6 F LUE T RANSPORT S UPERVISION 15
6 PUTTING INTO OPERATION AND ADJUSTMENT 15
6.1 G ENERAL 15
6.2 S TART BY USING THE THERMOSTAT 15
6.3 S TART THROUGH THE DISPLAY IN THE HEATER 16
7 ADJUSTING THE GAS-CONTROL 16
8 PROBLEM SOLVING 17
8.1 G ENERAL 17
9 MAINTENANCE / SPARE PARTS 20
9.1 G ENERAL INSPECTION 20
9.2 I NSPECTION OF THE HEATER 20
9.3 I GNITION ELECTRODE 20
10 EXAMPLES ELECTRICAL INSTALLATION: 20
10.1 T HERMOSTAT CABLE 20
10.2 I NSTALLATION WITH MODULATING ROOM THERMOSTAT 21
10.3 I NSTALLATION OF MORE HEATERS ON ONE THERMOSTAT 21
11 ELECTRICAL DIAGRAM 23
12 EXPLODED VIEWS AND SPARE PARTS 24
12.1 S PARE PARTS 24
12.2 E XPLODED VIEW XR10-30 24
12.3 E XPLODED VIEW XR40-60 25

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 3/25
2Genera
2.1 Safety warnings
The installation and maintenance of this air heater should be performed by an authorized
qualified competent installer in accordance with this manual, using calibrated equipment.
This heater must be installed in accordance with the manufacturer's instruction and local codes.
The qualified installer needs to follow the local health and safety codes.
This appliance may only be operated and serviced by sufficient instructed people. Failing to
follow the instructions can lead to damage to the appliance or the installation.
This appliance can be used by children aged from 8 years and above and persons with reduced
physical, sensory or mental capabilities or lack of experience and knowledge if they have been
given supervision or instruction concerning use of the appliance in a safe way and understand
the hazards involved. Children shall not play with the appliance. Cleaning and user
maintenance shall not be made by children without supervision.
Always follow these safety instructions:
•Make sure that the area around the appliance is dry when working on the appliance.
•Always close the doors and inspection hatches unless adjusting and checking the heater.
Before working on an already installed heater:
- Set the thermostat to lowest setting.
- Close the main gas switch. The main gas switch should be situated upstream in the gas
line near the heater.
- Turn off all electric power to the appliance
After working on the heater always check for gas leaks.
Close the doors and hatches of the appliance.
2.2 Important checks before installation
2.2.1 Pre-check instructions
Before unpacking and installation, please check (i.e. on the data badge) if the heater is in
accordance with the order and if it is suitable for the local present provisions (gas type, gas
pressure, electrical supply etc.)
The heater has been tested in detail on safety and correct operating settings before leaving the
factory. It has been adjusted for the type of gas that is stated on the data badge. Should there
be any doubt, please contact your supplier.
2.2.2 Gas type
The unit is suited for OR Natural gas OR Propane gas. On the labels on the packaging and the
heater can the gas type that the heaters is set up for can be found. In case the heater needs to
be converted to another gas type contact your supplier. It can only be converted by the
manufacturer or its representative.
2.2.3 Standards
The Installation must comply with all applicable local and national standards.
The installation of the air heater must be in accordance with the relevant requirements of the
Gas Safety regulations (for example in GB; The Institute of Gas Engineers IGE UP-1 and 2),
building regulations and the IIE regulations also incorporating the gas safety (installation and
use) regulations. Other national and/or local regulations may apply (the Local Authority ,Fire
Officer and Insurers)

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 4/25
2.2.4 Protection from water and dust
The heater is not waterproof. This means that it may not be exposed to rain, spry or dripping
water. The IP classification is IP00B
The appliance is not designed for use in a very dusty environment. Dust may accumulate in the
heater and may cause a defect of the heater. This is also the case for the room-thermostat.
2.2.5 Protection against dust
The appliance is not designed for use in a very dusty environment. Dust may accumulate in the
heater and may cause a defect of the heater. This is also the case for the room-thermostat
2.2.6 Temperature
Do not install the heater in places where the temperature can rise above 35°C. At higher
temperatures the internal components will degrade much faster. This is not covered by the
guaranty.
2.2.7 Corrosive environment
The heater should not be installed in areas containing any corrosive or explosive vapours. It
should be prevented that chlorine or other corrosive containing vapours are sucked into the air
intake. These vapours will result in corrosion of the heat exchanger and a leakage of
condensate and flue gas. Defects caused by this are not covered by guaranty. Please consult
your supplier. This is also the case for the room-thermostat
2.2.8 Installation distances
Keep sufficient distance between the heater and any obstruction , in connection with safety and
access for service and maintenance. Pay particular attention to any flammable materials.
Please take into account the possibility to open the door of the heater for the necessary service
and maintenance work . Make sure the air flow to and from the heater is unhindered. Any
obstacles should be a minimum of 5 metres away from the front of the heater. Read the
chapter “Installation” carefully.
2.2.9 Maintenance
For the safe and proper operation of the heater periodical maintenance is necessary. When the
heater is not serviced and cleaned in time, it could lead to damage of the heater or its
surroundings.
2.3 Guarantee
The guarantee becomes void when the air heaters are not installed and serviced in accordance
with this manual.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 5/25
3Technica detai s:
Type XR 10 20 30 40 50 60
Maximum nominal heat input (Nett) kW 14,0 22,8 32,0 44,0 55,0 66,0
Minimum nominal heat input (Nett) kW 9,0 14,8 20,5 26,4 33,0 39,6
Maximum nominal heat input (Gross) kW 15,6 25,3 35,5 48,9 61,1 73,3
Minimum nominal heat input (Gross) kW 10,0 16,4 22,8 29,3 36,7 44,0
Maximum heat output kW 12,8 20,8 29,2 40,2 49,9 60,5
Minimum heat output kW 8,3 13,8 19,1 24,4 30,8 37,0
Efficiency @ max. power (Gross). % 91,4 91,3 91,1 91,4 90,7 91,7
Efficiency @ min. power (Gross). % 91,7 93,0 93,1 92,4 93,3 93,4
Max air output (warm) m3/hr 1.150 2.070 2.600 4.370 5.150 6.300
Throw horizontal (max) m 12 16 23 26 28 30
Throw vertical (max. warm) m 5 5 6 7 7 8
Gas connection G” 1/2” in 1/2” 1/2” in 3/4”out 3/4” out 3/4” out
Electrical Voltage (50Hz) Vac 230 230 230 230 230 230
Electrical Power max. kW 0,250 0,250 0,250 0,450 0,450 0,600
Electrical Power min. kW 0,250 0,250 0,250 0,450 0,450 0,600
Electrical Power stand by. kW 0,004 0,004 0,004 0,004 0,004 0,004
Electrical Current max. A 1,1 1,1 1,1 2,0 2,0 2,6
Emission efficiency, (ηs,flow) % 96,1 93,3 90,6 91,7 91,2 90,8
Seas. space heating efficiency % 76,3 74,8 72,8 73,8 74,1 73,7
NOx emission (GCV) mg/kWh 37 36 35 43 41 42
NOX class 5 5 5 5 5 5
Flue amount max. kg/hr 21,7 35,5 51,3 70,6 88,2 105.8
Thermostat comm.bus system (low volt.) Yes Yes Yes Yes Yes Yes
Sound level (average @ 4 meter) dBA 42 45 45 46 47 49
Min. suspension height horizontal throw m 1,7 1,7 1,7 1,7 1,7 1,7
Flue length max. m 9 9 9 9 9 9
Weight m 36 37 38 78 80 82
Natural
ga
s G2
0
,
heater version
3.3
Nominal supply pressure G20 mbar. 20
Supply pressure (min-max) G20 mbar. 17-30
Gas category I2H
Class B23, C13, C33
Max gas consumption G20 m3/hr 1,5 2,4 3,4 4,7 5,8 7,0
CO2 High G20 % 9,0 9,0 9,0 9,0 9,0 8,9
CO2 Low G20 % 8.5 8,5 8,5 8,5 8,5 8,5
Propa
n
e
, G31,
heater version
3.4
Nominal supply pressure G31 mbar. 30-50
Supply pressure (min-max) G31 mbar. 25-50
Gas category I3P
Class B23, C13, C33
Max gas consumption G31 kg/hr 1,1 1,8 2,5 3,5 4,4 5,3
CO2 High G31 % 10,7 10,7 10,7 10,7 10,7 10,5
CO2 Low G31 % 10,0 10,0 10,0 10,0 10,0 10,0

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 6/25

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 7/25
4Insta ation
4.1 Positioning
•Check that the support is solid enough.
•The heater is designed as free hanging. The heater
should be able to blow the warm air free from any ducting
or obstacles. Also the air intake should be free.
•Keep sufficient distance between the heater and any
obstruction , in connection with safety and access for
service and maintenance. See the drawings in this
chapter. Pay particular attention to any flammable
materials. Please take into account the possibility to
open the door of the heater for the necessary service
and maintenance work . Make sure the air flow to and
from the heater is unhindered. Any obstacles should be
a minimum of 5 metres away from the front of the
heater.
•The heater can be installed horizontally or on an angle
of maximum 45 degrees downwards.
•When the heater is installed other than horizontal,
Always re-adjust the CO2 setting from the gas valve.
•The heaters type 10 and 20 are provided with 2 off
M10 threaded sockets as fixing points (see the
dimension diagram).
•The types 30 and 40 have in the middle a M10 socket and also 4 sockets on the top corners
of the heater
•The types 50 and 60 have on the top and bottom 4 M10 sockets. (see drawings)
•Use preferably the Winterwarm suspension kits.
•Make sure that after fitting, there is no mechanical tension on any connecting gas or electric
supplies.
•If the heater is installed with the air stream vertical downwards the maximum suspension
height is 8 meters. Otherwise the warm air will not reach the floor.
Attention:
See the application-restrictions in this manual (Chapter 2) for further installation restrictions.
min 250
10 t/m 30 min. 500 mm
40 t/m 60 min 660 mm

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 8/25
Available suspensions:
Standard bracket Design bracket
Horizontal or vertical horizontal/vertical rotatable
XR10-30: GA.8610 XR10-30: GA.8630
XR40-60: GA.8620
Suspension kit: vertical Suspension adapter XR10-30
GA.8645 for M10 threaded bar
GA.8690

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 9/25
4.2 Gas connection
The gas supply line has to meet the national valid requirements and possibly the local
requirements of the building inspector, police or fire brigade. (In GB it must comply with Gas
Engineers publication UP-1 and UP-2 together with BS 6891.
A manual isolation valve in the supply line must be placed within reach of the heater, and all gas
lines must be mounted without any mechanical tension.
When testing the supply lines with pressures above 60 mbar, this manual valve at the heater
must be closed.
The working and standing supply pressure must be a minimum of 17 mbar, and a maximum of
30 mbar ,measured at the inlet pressure nipple of the gas control in the heater
In case the heater needs to be converted to another gas type contact your supplier. It can only
be converted by the manufacturer or its representative.
4.3 Electrical connection
4.3.1 230Vac supply
The installation must comply with local and
national requirements, ( as well as IEE
regulations)
Never use a room thermostat to interrupt the
electrical supply to the heater!
Make provisions to completely isolate the heater for maintenance purposes. This can be an
isolation switch (min.3mm contact opening gap) , a power plug or a non-switched fuse spur.
The wiring diagram for the heater can be found towards the end this manual.
The supply is 230Vac. with earth. The control circuit is a two wire low voltage bus
communication.
4.3.2 Room thermostat
The heater can only be controlled by special modulating Winterwarm room thermostats:
The Multi Therm Comfort; modulating digital clock thermostat with optimiser. It can control 1 to
8 air heaters HR10 up to HR60 or 1 to 4 air heaters HR80 up to 120.
The Multi Therm Standard; modulating digital thermostat. It can control 1 to 8 air heaters
HR10 up to HR60 or 1 to 4 air heaters HR80 up to 120.
The Interface printboard; special designed interface module for connecting the air heaters with
Building Mangagement Systems. (0-10V (modulating input) signal, high/low signal,
external reset and other different in and outputs.
ON/OFF thermostat
The heater cannot be controlled with a simple on/off thermostat.
In all cases the communication between heater and thermostat is based on a two wire, low-
voltage connection. In the appliance the wire for the thermostat has to be connected to
connection 4 and 5 (see also electrical wiring diagram) Attention: This also needs a change in
the settings on the print board.
4.3.3 Thermostat installation
When mounting the thermostat, take attention to the following items:
•Mount the thermostat in a place where the air can circulate free pass the thermostat. Take
notice that the sun does not shine directly upon the thermostat (in the winter). Do not
place the thermostat on a cold wall. Place the thermostat on an inner wall free from
draught.
•Never place the thermostat within the throw of the heater.
•Never mount the thermostat near aerials of internal communication networks. These emit
radiation that could lead to disturbance of the thermostat. Always keep some meters
distance.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 10/25
•In all cases the communication between the heater and the thermostat is based on a two
wire, low-voltage connection. In the appliance the wire for the thermostat has to be
connected to connection 4 and 5 (see also electrical wiring diagram).
Cable specification: signal cable, 1x2x0,8 (shielded and twisted)
Maximum length 250m.
If the cable is chosen too thin, the signal will become too poor. If the cable is not shielded and
twisted the signal might become disturbed in an EMC unfriendly environment.
Keep the thermostat cable separated from mains cables. Connect the earth shield of the cable
only to the earth terminal in the heater.
If these guidelines are not followed it may result in malfunction of the installation or worse, it
could damage the thermostat or the electronics in the heater.
4.3.4 Fuse
On the heater control board there is 1 fuse. See electrical wiring diagram.
F1 and in the power supply of the heater. Replace the fuse only by a fuse of the same type, 5AT
4.4 Air intake / combustion products discharge
Check for compliance with local / national regulations.
Only the described flue material may be used. This goes for the roof or wall terminal and also
for the piping between the heater and the terminal. Only so the installation is approved.
Do not use terminals for condensing appliances. This can lead to water inside the flue system.
In some cases the roof terminal has to be at least 0,5m above roof level (depending on local
regulations).
Pay attention on fresh air ventilation openings on the building. There are local distance
restrictions on placing a flue terminal near the ventilation openings.
4.4.1 Flue material
It is only allowed to use CE marked flue material from the manufacturer Muelink & Grol (M&G)
and Burgerhout, type Alu-fix temperature class minimum T250. These Flue systems can be
bought at your supplier.
Only use one flue pipes from the same diameter as the flue spigots on the heater.
Different manufacturers have different connections systems from the flue pipes. It is not allowed
to combine systems from different manufacturers.
4.4.2 Maximum flue length
The maximum pressure drop in either the air supply pipe, or the flue pipe ,must not exceed 9
metres straight pipe , excluding the terminal. Whenever bends are used the pressure drop is
greater and therefore a 90°bend will count as 2 metres and a 45°bend as 1 metre. All flue
pipes must be of the same diameter as the flue spigots on the heater, and all flue joints must be
sealed. For further information regarding the flue system please contact your reseller.