Installation and Maintenance Instructions.THESE INSTRUCTIONS MUST BE READ FULLY BEFORE COMMENCING INSTALLATION.

Owner / installer: The life of this apparatus and its efficiency 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 efficiency or loss of ventilation, will result in the CE Certification and Hydor’s warranty being cancelled.

Indirect Combustion Gas Heater

incorrect

correct, minimum height 5mm

Please take note of the following symbols used within this document:

Warning: Hazards associated with electric current and high voltages

Important: Important information

Hydor’s policy is one of continual improvement and the right to change a specification at any time without notice is reserved. Whilst every care has been taken to ensure that the contents of this document are correct at time of publication, Hydor shall be under no liability whatsoever in respect of such contents.

Hydor cannot guarantee the operation of any equipment unless all documented instructions are complied with, without variation. Hydor is a registered trademark of Hydor Ltd and is a member of Elta Group. All other trademarks, trade names or company names referenced herein are the property of their respective owners.

1. General1.1 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.

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 Characteristics2.1 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

CodeCalorific

Output (kW)Usable

power (kW)Efficiency

(%)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

CodeSmoke 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

CodeElectrical 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 4 0/+40 225

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. Installation3.1 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.

2.3 Dimensions

E

F

B

A

C D

G

Code A B C D E F GWeight

(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

0,6

m

6 m mini

1 m

min

i

0,9 m mini

0,5 m

0,5 m

3.4 Ensure there is free space around the heater and for efficient 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 sufficient 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 sufficient 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..

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 on the following page.

Be careful, make sure to always use lock nuts to ensure the fastening.

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.

2

1

3.8 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.

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 realised 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 off before any operation on the line. Electrocution hazard.

REGULATION

HEATER

Reset

Pilot wire

Live

Diode

Diode

Heating

Ventilation

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 Stop4.3 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.

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)

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

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)

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

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 Connection5.1 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 sufficient 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 regulationconnector

Fan connector

Burner resetBurner default

Burner connector

3

1

2

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

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 off.

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

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G2

0

Regulator Pressure

Low Speed 4.5 4.5 4.5

High Speed 7 7.5 7.5

Gas ramp injectors 8 x AL 2.50 12 x AL 2.50 16 x AL 2.50

Extractor washes - 35 30

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for

G2

5

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

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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

6.3 Adjustment table for stage 2 valve

Types CBI 50 CBI 76 CBI 98

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G2

0

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

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just

me

nt

for

G2

5

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

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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

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.

7. Commissioning7.1 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 differential 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 off 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 differential 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 off the burner should the temperature exceed 90°C.

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 by a qualified professional person.

9.1 Correct and regular use and maintenance of the unit heater allows an efficient 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 off.

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.

9.4 The heat exchanger can resist to a high pressure cleaner and can be cleaned with water. The upper access door allows a good angle to clean the heat exchanger. And the two lateral metal plates allow a good access to the rear of the heat exchanger bends. The water will flow towards the lower access door.

WARNING: Do not clean the burner compartment or the fan with high pressure jet! Do not get wet the electrical parts, ELECTRICAL HAZARD. Do not spray through the doors, it can damage the door gasket. Do not spray directly on temperature sensors. 10. Troubleshooting10.1 In case of problems, make sure that the conditions required prior to operating the heater are present. If the control box is in the safety position (with the burner defect indicator lamp lighted up), reset it.

WARNING: All electrical or mechanical operations must be carried out when the electrical supply is cut off and the gas supply is closed.

Defect Cause Remedy

The device does not start

Incorrect wiring. Lack of voltage. The ambi-ent thermostat is not triggered. The pilot wire receptor is not on automatic position. Overheat safety thermostat is triggered

Check the wiring. Verify the electrical. Increase the setting point of the ambient thermostat. Check the positiion of the receptor switch inside the heater. Reset the thermostat.

The burner preventilates continuously

Extractor out of service. Air pressure switch disconnected. Air pressure switch out of services.

Replace the extractor. Reconnect the pressure air pipes. Replace the air pressure switch

The ignition electrode is sparking, the burner ignites, the control box turns on safety position (the burner default lights)

Gas valve defective. Control box defective. Ionization sensor incorrectly adjusted or defective. Air in the piping. No gas

Replace it. Adjust it. Bleed the piping. Check the pressure.

The unit tunrs on safety position (red LED switched on)

Gas supply interruptedReset by pressing the red button on the control box

Cold air when startingIncorrect adjustment of internal thermostat

Check the adjustment of the ventilation thermostat (adjustment 35°C)

The device does not heat sufficiently

Incorrect placing of the thermostat. Incorrect adjustment of the thermostat. Insufficient gas pressure. Injectors are unsuitable.

Change its location. Adjust the thermostat. Check the gas supply pressure. Check that the injectors are correctly selected and replace them if necessary.

The device never stopsThermostat is set too high or is defective. Incorrect wiring.

Lower the setting point or replace it. Check the wiring.

11. Recommendations for the end user Precaution to be respected:11.1 Never obstruct the smoke exhaust system and the fresh air intake.11.2 Never make any modifications to the adjustments which have been carried out by the qualified professional person.11.3 Never spray any water into the gas heater11.4 Warn the after-sales technician when there is a change of gas, gas pressure or a modification of the power supply voltage.

You are strongly recommended to take out a maintenance contract: "see with your installer''.

11.5 What should be done in case of problems?

Problems Remedies

Smell of gasClose the external gas valve and the electricity supply then warn the maintenance technician.

The burner stays in safety position (burner defect led is lighted)

Press the reset button of the burner located on thermostat control box. If the problem persists, contact the after sales technician.

11.6 If you smell gas, immediately close the external gas valve to isolate the gas circuit and the electrical supply.11.7 Open doors and windows to NATURALLY ventilate the contaminated atmosphere. Contact the installation engineer, who must have a current GAS CARE CERTIFICATE.

11.8 Useful numbers: 11.8.1. Robin HIbberd (Hydor) - 07595086439. 11.8.2 Shaun Morris (Hydor) - 07944172311.

Do not use the Heaters until the fault has been rectified and passed safe.

12. Precautions12.1 Never obstruct the smoke exhaust system or the air intake.12.2 Never spray any water into the gas heater. 12.3 Never have combustible objects within the "safe" distance around the gas heater. 12.4 Never make any modifications, which should always be done by a Certified Technician. 12.5 Warn the Maintenance Technician of any changes to the gas, gas pressure or the modification to power supply system.

You are strongly recommended to take out a maintenance contract with your Installer or a Certified Gas Care Technician. Hydor are able to offer this Service.

Notes

Notes

Notes

GuaranteeHydor or its agents will, within a period of one year from the date of dispatch from their works, at its option, replace any goods, which are proven to have defects as a result of defective materials or workmanship. The goods must be inspected by a Hydor official and if necessary returned, with a Returns Note Number, carriage paid, for further examination.

Hydor Ltd

Hydor

Unit 8, Parkers Close, Downton Business Centre, Downton, Salisbury, Wiltshire, SP5 3RB, UK

Tel: +44 (0) 1725 511422Email: info@hydor.co.ukWeb: www.hydor.co.uk

idealair group

Unit 1, Building 1, Sydney Corporate Park,85 O’Riordan Street, Alexandria NSW 2015

Tel: +61 (02) 8073 3310 Fax: +61 (02) 8073 3320 Email: info@idealairgroup.com.au

AMS

11 Ingrid Road, Montague Gardens,7442 Cape Town, Western Cape

Tel: +27 (0) 21 552 1077Fax: +27 (0) 21 552 2797

Inst Issue 2: 09.19