IDS 100 - Heating TROTEC - Free user manual and instructions

USER MANUAL IDS 100 TROTEC

1. 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:

1 Operating manual 10 Wheel 2x 2 Assembly instruction manual 11 Locking pin 2x 3 Oil heating unit ISD 100 12 Spacer ring 2x 4 Chimney connection 150 mm 13 Hexagon nut 4x 5 Handle 14 Hexagon screw 4x 6 Support 15 Screw 4x 7 Hexagon nut 4x 16 Outlet cone 8 Hexagon screw 4x 17 Assembly tools 9 Support bracket for axis

3. Guarantee provisions

The warranty period granted for the oil heating unit IDS 100 shall be 12months. 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.Operating manual – IDS 100 B-2 EN

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 explosive environments. 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 cooled down 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 devices or device parts.

• Do not use the device if you detect any damage to its plug and cables. 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 at its plug.

• Do not touch electrical connection cables when your hands are wet!

• Protect the electrical connection cables against damage caused by, 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 does happen 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 of the device.

• Do not reach into the existing openings.

• Do not leave children or animals unattended near the operating device!

• Do not operate the device in rooms with insufficient supply of combustion air.

• Avoid the improper use of fuels. Risk of environmental pollution!

• Do not let any leaked fuel seep away into the soil and prevent it from entering the sewer system.

5. Function and product characteristics

The oil heating unit IDS 100 is used to heat up room air in order to achieve a fast hea ting 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.

75 °C Oil consumption max.10.79 l/h Tank capacity135 l Air transportation hose connection

1 x ø 500 mm, L-max = 6 m Air transportation hose connection

1 x ø 400 mm, L-max = 6 m Chimney connectionø 150 mm Thermostat connectionseries Combustionindirect Nozzle2.00-80° W (gal/h) Sound pressure level (at distance of1 m) 76 dB (A) Length1918 mm Width731 mm Height1220 mm Weight 149 kg Fuse16 A indicates the temperature increase. ΔT + ambient temperature = exhaust air temperature optionalOperating manual – IDS 100 EN B-3 Fuels The following fuels have been approved for use with the oil heating unit IDS 100: heating oil EL, diesel

7. Proper and improper use

Proper use The oil heating unit IDS 100 has been developed for the generation 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 can be used in conjunction with an air transportation hose. 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 on a fireproof surface.

• The device must be installed near a chimney or external wall.

• The device must be connected to a properly secured mains socket.

• The installation room of the device must be sufficiently ventilated.

• The minimum distance of the intake opening of the device to the wall must be at least 1 m (see figure). min. 1 m

• The minimum distance of the device to inflammable materials must 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 available.

9. Description of device

The oil heating unit IDS 100 consists of the following components: Oil heating unit

1 Combustion chamber 8 Heating oil filter 2 Burner 9 Heating oil circuit 3 Nozzle 10 Support and handle 4 Pump 11 Wheel 5 Solenoid valve 12 Tank 6 Fan motor 13 Burner motor 7 Fan 14 Combustion air regulator Control panel

1 Reset button with indicator lamp 4 Change-over switch, power stage 2 Selector switch (high-low) (ventilation/heating, thermostat operation) 5 Lamp 3 Thermostat socket 6 Power supply cableOperating manual – IDS 100 B-4 EN

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 Trotec customer service or the specialist dealer from whom you pur- chased the device.

• Check the oil heating unit and its connection parts for possible damages.

• Mount the support, the handle, the wheels and the outlet cone to the oil heating unit. Please refer to the supplied assembly in- struction manual for further information. Please use the supplied assembly tools.

• Make sure to comply with the requirements described in the chapter "Installation conditions".

• Correctly connect the exhaust system of the device to a chimney or an external wall as shown in the chapter "Exhaust system".

• Fill the heating oil into the tank with the device switched off and cooled down.

• Inspect the device prior to commissioning and check it regularly for 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 fan can move freely before plugging the power plug into the mains socket.

• Connect the power supply cable to a properly secured mains socket (230 V / 50 Hz / 10 A). On construction sites, a residual current circuit breaker must be connected upstream of the mains socket 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".

• Before planning the installation of the exhaust system, the local chimney 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 craftsman!

• Make sure that an unobstructed and sufficient supply of com- bustion air is provided (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

A min. 1 m 1 Wall duct with pipe elbow min. 5° B min. 1 m 2 Chimney - min. internal dimensions 20x20 cm C as short as possible 3 Opening for cleaning with explosion D ≥ ø 150 mm protection cap E min. 1 m 4 External wall 5 Draft reinforcement, H-shaped

12. 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:

The device can operate in manual mode.Operating manual – IDS 100 EN B-5

• Switch the device on by setting the selector switch to the position

" (ventilation). The fan motor is started while the burner remains switched off.

The 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.

• To be able to connect the thermostat, you must mount the provid- ed thermostat socket. To this end, connect the power supply ca- ble to the connection terminals 2 and 3 of the thermostat socket. The removed conducting wire that connected the two connection termi- nals is to be reinstalled if the device is to be operated without thermostat.

• Switch the device on by setting the selector switch to the position "+ " (heating, thermostat operation). The fan motor and burner motor are started and the combustion will start after a few seconds. 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.

• Select the heating capacity of the device by setting the change- over switch to the low power stage (I S) or to the high power stage (I I S) (see figure). I I S I S 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 low temperature). The flame is extinguished and the fan will continue running for approx. 90seconds 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 again by 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 operation is automatically resumed if the voltage has stabilised in the range of 190 V to 250 V If the device has triggered the safety shutdown:

• Press and hold down the reset button for 3 seconds in order to resume 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 during start-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 occurred In order to determine the cause of the fault:

• see chapter "Troubleshooting"Operating manual – IDS 100 B-6 EN

• Switch the device off as described in the chapter "Functions and operation".

• Wait until the device has cooled down completely.

• Before transporting or adjusting the device, check if the tank cap is 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.

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 and operation".

• Wait until the device has cooled down completely. Cleaning after every 50 operating hours

• Dismount the heating oil filter. Remove the filter insert and clean it using clean heating oil.

• Dismount the upper housing part and clean the inner part as well as the fan blades using a cleaning fleece and a brass brush if it is heavily soiled.

• Check the condition of all cables and high-voltage connections.

• Dismount the burner and clean its components using a brass brush.

• Clean the electrodes. Check the distance of the electrodes and adjust it if required (see figure). 3 mm

• 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 painted and plastic surfaces may not be scoured. Do not use any solvent- based cleaning agents.

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 7 D-52525 Heinsberg Tel.: 49 (0) 2452 / 962 - 400 Fax.: 49 (0) 2452 / 962 - 200 Email: info@trotec.de www.trotec.de.

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.Operating manual – IDS 100 EN B-7 ProblemReset buttonCauseError correction Operation indicator Self-diagnostic indicator Fan does not start running and flame is not ignited switched off-Control device is incor- rectly set - Check if the control equipment is correctly set (e.g. the temperature set at the thermostat must be higher than the room temperature). Control device defective- Have the control device replaced by the customer service. Fan does not start run- ning or switches off dur- ing start-up or operation flashing orange light -no power supply- Check the characteristics of the electrical system (230 V -1~ - 50 Hz). - Check the function and position of the selector switch. - 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 operation continuous red light flashing orange light Flame is present prior to the ignition of the trans- former - Contact the customer service and have the device cleaned and heating oil residues removed from the combustion chamber. Photoelectric cell defective- Have the photoelectric cell replaced by the cus- tomer service. flashing red light or flashing red/ green light Motor winding interrupted or blown - Have the motor replaced by the customer service. Motor bearing blocked- Have the motor bearing replaced by the customer service. Motor capacitor blown- Have the motor capacitor replaced by the cus- tomer service. no ignition- Check the connections of the ignition cables to the electrodes 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 customer service. Flame control system de- fective - Have the flame control equipment replaced by the customer service. Photoelectric cell defective- Have the photoelectric cell cleaned or replaced by the customer service. Burner is not or only in- sufficiently supplied with heating oil Contact the customer service in order to: - have the integrity of the coupling between the pump and motor checked. - have the heating oil circuit checked for air that may have entered the circuit and to have the tight- ness of the lines and filter seal checked. - have the nozzle cleaned or replaced.Operating manual – IDS 100 B-8 EN ProblemReset buttonCauseError correction Operation indicator Self-diagnostic indicator Solenoid 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 orange light Internal error of the elec- tronic control unit Contact 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 formation continuous green light

insufficient supply of com- bustion air - Remove all obstacles or blockages from the intake and/or exhaust openings. - Have the position of the air setting ring checked by the customer service. - Have the support disc of the burner cleaned by the customer service Supply of combustion air too high - Have the position of the air setting ring checked by the 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 filter checked by the customer service insufficient heating oil quantity at the burner Contact the customer service in order to: - have the pump pressure value checked. - have the nozzle cleaned or replaced. too much heating oil at the burner Contact the customer service in order to: - have the pump pressure value checked. - have the nozzle replaced. Device does not switch off continuous green light

Solenoid valve seal defec- tive - Have the solenoid valve replaced by the customer service.Operating manual – IDS 100 EN B-9

Circuit diagram AP Control unit FO Photoelectric cell TA Thermostat connection CO Capacitor ST Indicator lamp MV Fan motor FU Fuse MB Burner motor LI 1 Safety thermostat FUA Fuse LI 2 Overheating protection, thermostat, L1 RV Selector switch EV 1 Solenoid valve I° stage FA Air regulator EV 2 Solenoid valve II° stage IT Ignition transformer LF RFI filter RF Heated filter (optional) DV Change-over switch, power stage (high-low) TF Plug for heated filter TD Transformer Setting of the air setting ring