Powrmatic VPC 30 User, Installation And Service Manual

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User, Installation and Servicing

Instructions

WARNING: THIS APPLIANCE MUST BE EARTHED

£2.50 When supplied separately.

VP Classic Range Users, Installation and Servicing Instructions Issue 2 April 2009

The VPC Range

Dear Customer

This is to certify that this appliance is guaranteed for two years including parts and

labour from the date of original commissioning.

The heat exchanger, where fitted, is guaranteed (parts only) for a further eight years,

chargeable on a sliding scale basis, price relative to age.

To make a claim

In the first instance you must contact your appliance supplier, or installer and

provide:-

1. The appliance type and serial number.

2. The original commissioning documentation.

3. As much detail as possible on the fault.

Your supplier, or installer will then contact Powrmatic to make a guarantee claim

on your behalf.

Conditions of Guarantee

1. The appliance must have been installed by a competent recognised installer,

and in accordance with the manufacturers instructions, building regulations and

local regulations.

2. The appliance has been professionally commissioned.

3. The appliance has been maintained on a yearly basis by a competent servicing

company.

4. The appliance has been used in accordance with the manufacturers instructions.

5. The correct specification fuel has been used

6. No unauthorised repairs or modifications have been made.

7. Powrmatic General Conditions of Sale have been observed.

8. Except for the obligation of Powrmatic Ltd to perform warranty repairs during

the guarantee period, Powrmatic will not be liable in respect of any claim for

direct or indirect consequential losses, including loss of profits or increased costs

arising from loss of use of the appliance, or any event arising there from.

Exclusions

1. Gaskets and fan belts are not included in the guarantee

Important: This certificate must

be kept with the appliance

Certificate of Guarantee

Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS

tel: 01460 53535 fax: 01460 52341

email: guarantee@powrmatic.co.uk web: www.powrmatic.co.uk

1. First Start Sequence

Follow the sequence below before lighting the heater(s) for the

first time.

a) Ensure that the gas supply to the unit is turned OFF.

b) Turn on the electrical supply to the heater and programme

the controls in accordance with their instructions.

Note:The igntion sequence may start during this process

but the heater will not light, as the gas supply is turned off,

and the internal burner control will go to lockout. The lockout

indicator on the external control will be illuminated.

c) Ensure that the controls are not calling for heat i.e. the

thermostat is at minimum or the clock control is set to an

OFF period or the function switch is set to OFF.

d) Check that all warm air delivery outlets are open.

e) If necessary reset the internal control from lockout by

pressing the reset button on the external control for 3 seconds.

f) Check that the overheat reset button has not operated.

g) Ensure that the Summer/Winter switch is in the Winter

position.

h) Turn ON the gas supply.

2. Lighting the Air Heater

NOTE:

On initial lighting of the heater(s), it may take some time to

purge the internal pipework of air. If it is not possible to light

the heater after several attempts contact the local service

company.

1. Set the controls to call for heat and the ignition start up

sequence will commence. The internal exhaust fan will run.

When sufficient combustion airflow is proved by the air pressure

switch the ignition spark will be generated and the main gas

valves energized. The burners will then light.

2. If the burner fails to light the control box will attempt two

further ignition attempts before going to lockout. The lockout

light on the MC100 or Powrtrol will be illuminated (Note: If

an integral MC100 or Powrtrol are not used a remote lockout

indicator/reset will be fitted). To restart the ignition sequence

depress the reset button on the control for at least 3 seconds.

If the unit will not light after four or five attempts then shut

down the unit and call in a service engineer.

3. To Shut Down the Air Heater

3.1 For Short Periods:Turn the room thermostat to the OFF

or lowest setting.

3.2 For Long Periods:Complete step 3.1 above. Wait for 5

minutes and then turn OFF the

electrical supply at the isolator.

4. Description of Operation

Important:

All heaters must be controlled by the fitted external

controls and not by use of the main switch in the electrical

supply to the heater.

4.1 Standard Units

The ignition sequence will commence each time that the external

controls e.g. Timeclock, room thermostat etc. call for heat.

Approximately 15 - 30seconds after the main burners light the

heater fan will be automatically started. When the external

controls are satisfied the main burners will be turned off and

approximately 2 - 3 minutes later the heater fan will be

automatically stopped.

4.2 High / Lo & Modulating Units

When the main burners are alight the heat output will be

controlled either to high fire or low fire or, in the case of

modulating units, to any point between high and low fire;

depending on the requirements of the space being heated and

the control system.

4.3 Summer / Winter Modes

The integral MC100 or Powrtrol controls, and certain types of

external controls, will provide for two modes of operation i.e.

Summer:The heater fan alone will run at the dictate of the

external controls to provide air movement.

Winter:The heater will operate normally.

5. Maintenance

Regular servicing is essential to maintain efficient, reliable and

safe operation of the heater. Users are strongly recommended

to have the heater serviced by a qualified person at least annually

and preferably at the end of the heating season.

6. IMPORTANT

Free access must be maintained to and around the heater for

servicing purposes and the air supply to the heater must not be

restricted in any way. Combustible materials must not be stored

adjacent to the heater.

If at any time a gas leak is suspected turn OFF the gas supply

- DO NOT USE A NAKED FLAME - and contact the local

gas undertaking immediately.

All Powrmatic heaters use gas and electricity to power them,

they may also contain moving parts such as pulley belts. It

would be hazardous to tamper with or attempt to service unless

you are a competent person in the field of Gas and Electrical

work.

If you have any safety questions reference the servicing and

installation of any of our heaters please do not hesitate to contact

our head office for expert advice.

Your safety is paramount to us.

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed, adjusted and, if

necessary, converted by qualified persons* in accordance with

the current issue of the above regulations. Failure to install

appliances correctly can lead to prosecution. It is in your own

interests and that of safety to ensure that the law is complied

with.

* e.g. Corgi Registered

Users Instructions

CONTENTS

Section

Title

Page

Introduction

Technical Data

General Requirements

Installation

Air Distribution System

Commissioning & Testing

Servicing

Fault Finding Flow Chart

Wiring Diagrams

10.

Short List of Parts

Tables

Title

Page

Dimensions

Specifications

3.1

Injector Sizes & Burner Pressures

Natural Gas - Group H - G20

Electrical Loadings 1ph

Figure

Title

Page

Minimum Clearance Distances

2a.

Exhaust only System - Horizontal

2b.

Exhaust only System - Vertical

3a.

Individual System - Horizontal

3b.

Individual System - Vertical

Controls Layout

Honeywell VR425AB1007

Honeywell VR4605AB1027

High/Lo and Modulating Heads

Ignition Electrode Spark Gap

10.

Thermostat Fan/Limit - Honeywell L4064N

1. INTRODUCTION

The VPC range are highly efficient gas fired, fanned circulation

floor standing air heaters that cover heat outputs of 30kW to

130kW. The units have a single closed flue system that can be

either vertical or horizontal and feature a single burner assembly

which, as standard is ON/OFF but can also be supplied in

High/Low or Modulating formats. High/Low or Modulating

formats give a turn down facility of approximately 2:1. The

heaters are certified for use on Natural Gas, Group H - G20,

and Propane - G31 only.

Appliance Categories are Cat II2H3P (GB, IE).

The heaters intended primarily for heating commercial or

industrial premises. They must not be used where the atmosphere

inside the premises could be contaminated e.g. Dust, oil mist

etc. or in areas classified as hazardous as defined in BS 5345:

Part 2. They are not suitable for siting externally.

VPC heaters have a centrifugal fan assembly fitted at the base

of the heater to circulate the air being heated past the folded

tube heat exchanger.

Heaters are fitted as standard with one set of atmospheric inshot

burners having a fully automatic control for ignition, flame

sensing, gas supply control and safety functions and an internal

exhaust fan, as well as the main air fan(s) and limit thermostat.

Gas Safety (Installation & Use) Regulations

It is law that all gas appliances are installed, adjusted and, if

necessary, converted by qualified persons* in accordance with

the current issue of the above regulations. Failure to install

appliances correctly can lead to prosecution. It is in your own

interests and that of safety to ensure that the law is complied

with.

* e.g. Corgi Registered

2. TECHNICAL DATA

DØ

Table 1. Dimensions

Unit

VPC 30

VPC 52

VPC 110

VPC 80

VPC 130

189

1108

1412 750

1676

2043

100

130

1046

Gas entry

DØ

238

1767

2132

2209

1049

132

134

286

340

VPC 30UF shown

Front View

Sidet View

Front View

Sidet View

VPC 130UF shown

Side Duct Spigot

658(h) x 658(w)

658(h) x 960(w)

658(h) x 1315(w)

Top Duct Spigot

648(h) x 658(l)

648(h) x 960(l)

648(h) x 1315(l)

Alternative flue &

combustion air

positions

Alternative flue &

combustion air

positions

Inlet pressure

20mbar

Table 3.1

Injector Sizes & Burner Pressures Natural Gas - Group H - G20 Net CV (Hi) = 34.02MJ/m³

Inlet

INJECTORS

High Fire

Low Fire

Pressure

Burner

Gas Rate

Burner

Gas Rate

20mb

Pressure

MODEL

No.

Size Markedmbar

m³/h

mbar

m³/h

VPC 30

1.94

194

13.8

3.45

4.6

2.02

VPC 52

1.94

194

10.4

5.98

3.0

3.22

VPC 80

2.54

254

9.0

9.19

2.1

4.44

VPC 110

3.00

300

11.5

12.64

3.2

6.50

VPC 130

3.00

300

11.8

15.52

3.6

8.26

Table 2 - Specifications

MODEL

INPUT

(Nett)

OUTPUT INPUT

(Nett)

OUTPUT

m³/s

VPC 30

32.6

30.0

18.0

15.7

0.8664

VPC 52

56.5

52.0

30.4

26.1

1.5884

VPC 80

87.0

80.0

42.0

36.8

2.3372

VPC 110

119.5 110.0

61.5

53.3

2.9568

VPC 130

141.3

130.0

78.1

69.0

3.6288

0.370

178

0.55

248

1.8

305

2 x 0.55

362

2 x 1.10

410

HIGH FIRE

LOW FIRE

AIR

VOLUME

FAN

MOTOR

WEIGHT

c/w Heads

NOISE

LEVEL

dB(A) @ 3m

60.0

68.0

76.0

72.0

74.0

Available

static presssure

@ Std. Airflow

Table 4

Electrical Loadings 1ph

MODEL

VPC 30
VPC 52

3.6

7.4

3.3

8.7

5.4

VPC 80

32.8 15.0

VPC 130

22.0

7.8

NOMINAL

MOTOR

R.P.M.

PLATE

AMPS

(A)

START

AMPS

(A)

RUN

AMPS

(A)

18.5

10.3

5.8

5.8 +3.0

13.6

900
900
950

1400 + 900

4.7 x 2

750 x 2

ELECTRICAL

SUPPLY

230V 1N
230V 1N
230V 1N

400V 3N

POWER

INPUT

(kW)

0.80
1.10

3.0

2.37

3.145

400V 3N

VPC 110

150

200

225

150

200

Inlet pressure

37mbar

Table 3.2

Injector Sizes & Burner Pressures Propane - G31 Net CV (Hi) = 88.00MJ/m³

Inlet

INJECTORS

High Fire

Low Fire

Pressure

Burner

Gas Rate

Burner

Gas Rate

20mb

Pressure

MODEL

No.

Size Markedmbar

m³/h

mbar

m³/h

VPC 30

1.36

136

21.7

1.33

7.0

0.74

VPC 52

1.25

125

27.0

2.31

8.0

1.24

VPC 80

1.55

155

24.1

3.55

6.0

1.72

VPC 110

1.94

194

26.5

4.89

7.0

2.51

VPC 130

1.94

194

25.0

5.78

7.9

3.19

3. General Requirements
3.1 Related Documents

The installation of the air heater(s) must be in accordance with

the rules in force and the relevant requirements of the Gas Safety

Regulations, Building Regulations and the I.E.E. Regulations

for Electrical Installations.

It should also be in accordance with any relevant requirements

of the local gas region, local authority and fire authority and

the relevant recommendations of the following documents.

Institution of Gas Engineers & Managers

IGE/UP/1 (Ed.2)

Strength and tightness testing and purging

of industrial and commercial gas installations.

IGE/UP/1A

Soundness testing and direct purging of small low

pressure industrial and commercial gas installations.

IGE/UP/2

Gas installation pipework, boosters and compressors

on industrial and commercial premises.

IGE/UP/10

Installation gas appliances in industrial and

commercial premises.

British Standards Code of Practice

BS 5588

Fire precautions in the design and construction of

buildings.

Part 2 :1985 Code of Practice for Shops

Part 3 : 1983 Code of Practice for Office Buildings

BS 6230:

1991 Installation of Gas Fired Forced Convection

Air Heaters for Commercial and Industrial Space Heating.

Those appliances having a gross input rating not exceeding

60kW viz. VPC30, and installed so as to take their combustion

air from within the building must be installed in accordance

with the relevant recommendations of the following document.

BS 5440

Flues and Air Supply for gas appliances of rated input

not exceeding 60kW (1st and 2nd family gases), Part 2 - Air

Supply

3.2 Location

The location chosen for the air heater must permit:

- the provision of a satisfactory flue system and an adequate air

supply.

- adequate space for servicing and air circulation around the air

heater.

The heater(s) must not be installed in conditions for which it

is not specifically designed e.g. where the atmosphere is corrosive

or salty. Standard units are not suitable for outdoor location.

Where the location of the air heater is such that it might suffer

external mechanical damage e.g. from overhead cranes, fork

lift trucks, it must be suitably protected.

VPC units are designed to operate within an ambient temperature

range of -10 to 25°C.

3.3 Gas Supply

3.3.1 Service Pipes

The local gas undertaking should be consulted at the installation

planning stage in order to establish the availability of an adequate

supply of gas. An existing service pipe must not be used without

prior consultation with the local gas undertaking.

3.3.2 Meters

A gas meter is connected to the service pipe by the local gas

undertaking or a local gas undertaking contractor. An existing

meter should be checked, preferably by the gas undertaking, to

ensure that the meter is adequate to deal with the total rate of

gas supply required.

3.3.3. Installation Pipes

Installation pipes should be fitted in accordance with

IGE/UP/2. Pipework from the meter to the air heater must be

of adequate size. Do not use pipes of a smaller size than the

inlet gas connection of the heater. The complete installation

must be tested for soundness as described in the above Code.

3.3.4. Boosted Supplies

Where it is necessary to employ a gas pressure booster the

controls must include a low pressure cut off switch at the booster

inlet. The local gas undertaking must be consulted before a gas

pressure booster is fitted.

3.4 Flue System

VPC units must be used with a closed flue system and have an

internal exhaust fan, mounted downstream of the heat exchanger,

to both assist the evacuation of the products of combustion and

to draw in air for combustion.

The flue should terminate in a freely exposed position and must

be so situated as to prevent the products of combustion entering

any opening in a building in such concentration as to be

prejudicial to health or a nuisance.

3.5 Combustion Air Supply

Where VPC units are to be installed within the space being

heated and take the air from combustion from that space then

for buildings having a design air change rate of less than 0.5/h,

and the heated space has a volume less than 4.7 m³/kW of total

rated heat input grilles shall be provided at low level as follows:-

(1)

for heaters of heat input less than 60 kW, the

total minimum free area shall not be less than 4.5 cm²

per kilowatt of rated heat input.

(2)

for heaters of heat input 60 kW or more, the total

minimum free area shall not be less than 270cm² plus

2.25 cm² per kilowatt in excess of 60 kW rated heat

input.

All air vents should have negligible resistance and must not be

sited in any position where they are likely to be easily blocked

or flooded or in any position adjacent to an extraction system

which is carrying flammable vapour.

Grilles or louvres should be so designed that high velocity air

streams do not occur within the plant room.

The basic minimum effective area requirements of the air vents

are as follows:

(a) Low Level (inlet)

(1) for heaters of total rated heat input less than 60kW:

9cm² per kilowatt of rated heat input.

(2) for heaters of total rated heat input 60kW or more:

540 cm² plus 4.5 cm² per kilowatt in excess of 60kW

total rated input.

(b) High Level (outlet)

(1) for heaters of total rated heat input less than 60kW:

4.5cm² per kilowatt of rated heat input.

(2) for heaters of total rated heat input 60kW or more:

270 cm² plus 2.25 cm² per kilowatt in excess of

60kW total rated input.

3.6 Air Distribution System

VPC units used in buildings having a low heat loss i.e. where

single units are required to cover a large floor area, and in

buildings with high roof or ceiling heights Calecon thermal

economiser units should be fitted to ensure even heat distribution

and minimise stratification.

Care should be taken to avoid impeding the air throw with

racking, partitions, plant or machinery etc.

Care must be taken to ensure that return-air intakes are kept

clear of sources of smells and fumes, and where there is any

possibility of pollution of the air by dust, shavings etc.,

precautions must be taken to prevent contamination.

If necessary suitable barrier rails should be provided to prevent

any combustible material being placed within 900mm of the

warm air outlets.

4. Installation of Air Heater(s)

4.1 General

Before installation, check that the local distribution conditions,

nature of gas and pressure, and adjustment of the appliance are

compatible.

The air heater must be installed in accordance with the rules in

force and the relevant requirements of any fire regulations or

insurance company's requirements appertaining to the area in

which the heater is located, particularly where special risks are

involved such as areas where petrol vehicles are housed, where

cellulose spraying is carried out, in wood working departments

etc.

The following minimum clearances for installation and servicing

must be observed.

RHS Clearance (looking at front of heater)

0.5m

LHS Clearance (looking at front of heater)

0.5m

Top of the heater to ceiling

1.0m

Rear of heater to nearest wall

0.5m

Front of heater to nearest wall

1.0m

Any combustible material adjacent to the air heater and the flue

system must be so placed or shielded as to ensure that its

temperature does not exceed 65 °C.

IMPORTANT:

Heaters shall not be installed in:-

a) Those parts of spaces within buildings that have been classified

as hazardous areas as defined in BS 5345 : Part 2.

b) Where there is a foreseeable risk of flammable particles or

gases or corrosion inducing gases or vapours being drawn into

either the heated air stream or the air for combustion.

c) In areas subjected to significant negative pressures due to

extract systems.

3.7 Electrical Supply

Wiring external to the air heater must be installed in accordance

with the I.E.E. Regulations for Electrical Installations and any

local regulations which apply. Wiring should be completed in

flexible conduit.

All standard heaters are supplied by 230V - 1N, 50Hz or 400V

- 3N, 50Hz depending on the size. The method of connection

to the main electricity supply must:-

- facilitate the complete electrical isolation of the unit(s)

- be in a readily accessible position adjacent to the unit(s)

- serve only the unit(s)

- have a contact separation of at least 3mm in all poles. See the

accompanying wiring diagram for the heater electrical

connections.

4.2 Fitting the Air Heater

If necessary consideration should be given to mounting the

heater on resilient pads, or equivalent, to minimise transfer of

noise and vibration to the structure of the building.

Floor mounted heaters must be installed on a level

noncombustible surface.

Heaters mounted at high level must be supported on a purpose

designed platform or framework that is suspended from vertical

drop rods, chains or straps or mounted on specifically designed

cantilever brackets from a non-combustible wall. The method

of installation support must be capable of adequately supporting

the weight of the unit

(See Table 2, Page 3)

and any ancillary

equipment. Before installing the heater the existing structure

must be inspected to ensure it is suitable. All supports should

be protected against the effects of rust or corrosion.

.Any combustible material adjacent to the air heater and the flu

system must be so placed or shielded as to ensure that its

temperature does not exceed 65 °C.

If the method of mounting allows for any movement of the

heater it is essential that all gas, duct, and electrical connections

to the heater are made with flexible connections to maintain

continuity of connection.

4.3 Flue/Combustion Air Duct System

All models are supplied as standard with a top flue outlet and

combustion air inlet.

4.3.1.1. Conversion to Side Flue Outlet

1.Remove the two blanking plates from the flue /combustion

a i r o p e n i n g s a t t h e s i d e o f t h e u n i t .

2. Disconnect the flexible pipe from the exhaust spigot.

3. Remove the four screws securing the exhaust spigot and

reposition the spigot to the side of the heater using the top

position. Refit the flexible pipe.

4. Remove the four screws securing the combustion air spigot

and reposition spigot to the side of the heater.

5. Refit the blanking plates to cover the holes in the top of the

heater.

4.3.1.2 Internal Combustion Air

1. If ducted combustion air is not required

(see Section 3.5)

fit

the mesh inlet plate (supplied loose) behind the unused

combustion air inlet hole.

4.3.2. General Requirements

See Figures 2a to 3b for the different types of flue installation.

In all cases the flue outlet socket must be connected via the

provided flue system to outside air. The maximum permitted

length of flue system is 6m, or 12m if the flue outlet only is

used. If an offset is required two sets of 45° bends may be used

each set being equivalent to 0.5m of flue length. The minimum

flue length (end of flue terminal to side or top of heater) shall

not be less than 1.3m.

All outer joints must be finished with the provided locking

bands. A smear of silicon grease to the inside of sockets will

assist in fitting components together. All flue and combustion

air ducts must be supported independently of the air heater. The

flue or flue/combustion air terminal must not be installed so as

to be less than:

- 300mm below an opening e.g. window, air brick etc.

- 200mm below eaves or gutter.

- 300mm from an internal or external corner.

- 1200mm from a surface facing the terminal.

- 1500mm vertically from another terminal on the same wall.

- 300mm horizontally from another terminal on the same wall.

- 2000mm from ground level.

1.0m

0.5m

Fig 1 Minimum clearance distances

5. Air Distribution System

5.1 General

VPC heaters, if required, can be used with duct work either to

more precisely define the point of air delivery, and /or provide

ducted return air or ducted fresh air inlet.The system should be

checked to ensure that the installation work has been carried

out in accordance with the design requirements.

Particular attention should be given to the correct arrangement

of delivery ducts and registers, return air ducts and grills and

general adequacy of return air paths.

Ensure that the total duct system resistance does not exceed the

available air pressure of the equipment supplied refer to Table

(Page 3)

. If the duct system resistance is less than the available

air pressure of the equipment supplied additional resistance

must be introduced e.g. by adjustment of duct outlet nozzles

and balancing of the duct system. Conversely if the duct system

resistance is greater than the available air pressure of the heater

supplied the system resistance must be reduced.

5.2 Room Thermostat Siting

If a separate room thermostat is used it should be fitted at a

point which will be generally representative of the heated area

as far as temperature is concerned. Draughty areas, areas

subjected to direct heat e.g. from the sun, and areas where the

air movement is relatively stagnant e.g. in recesses, are all

positions to be avoided for siting the thermostat.

The thermostat should be mounted about 1.5m from the floor.

Any room thermostat, frost thermostat, time clock etc. must be

suitable for switching 230V, 5A and must be of the 'snap action'

type to minimise contact bounce.

For electrical connections of external controls see the

accompanying wiring diagram.

4.3.3 Installation of Flue System

Note:

A terminal guard, as supplied by Powrmatic Ltd, must be

fitted to horizontal flue terminals.

4.3.3.1 Horizontal System - Side Outlet

1. Locate the position of the flue terminal, allowing for a slight

gradient running down from the heater to the terminal of 2° -

3° and cut a hole in the building wall to suit.

2. Fit the flue terminal, securing via the wall plate and weather

with silicon sealant or similar.

3. Fit the twin to concentric adaptor to the terminal section and

extend the flue and combustion air ducts to the heater using

straight lengths. Fit an adjustable length prior to the unit, to

facilitate flue disconnection for servicing. Extend the adjustable

lengths to make the final connection to the appropriate heater

inlet/outlet spigots.

4. Ensure that internal silicon sealing rings are in place and that

all tubes are pushed fully home. Secure concentric lengths with

the locking bands provided.

4.3.3.2 Vertical System - Top Outlet

1. Locate the position of the flue terminal cut a hole in the roof

to suit.

2. Fit the flashing and the flue terminal so that the lower edge

of the outer case is over the top of the flashing. Weather with

silicon sealant or equivalent.

Fit a condensate drain lenth into the flue socket on the heater

and an equivalent straight length onto the combustion air socket.

3. Fit the twin to concentric adaptor to the terminal section and

then extend down to the heater using straight lengths. Fit

adjustable lengths as the final connection pieces, to facilitate

flue disconnection for servicing. Extend the adjustable lengths

to make the final connection but do not exceed the maximum

extended length so as to maintain joint integrity.

Extend the drainage offtake of the condensate drainage length

to a suitable gully or drain.

4. Ensure that internal silicon sealing rings are in place and that

all tubes are pushed fully home. Secure concentric lengths with

the locking bands provided.

4.3.3.3 Internal Combustion Air Systems

1. Complete the run of flue sections from the terminal spigot

to the flue outlet socket of the heater generally as described in

4.3.3.1 and 4.3.3.2, ensuring that the internal silicon sealing

rings are in place.

2. Ensure that the mesh inlet plate has been fitted (see 4.3.1.2).

4.4 Gas Connection

To facilitate servicing a servicing valve and downstream union

must be fitted at the inlet to the air heater. The gas supply to

the air heater must be completed in solid pipe work and be

adequately supported. Heaters suspended by drop rods, straps

or chains must have a flexible connection as the final link

between the gas supply pipe work and the heater. Sufficient

slack must be left in the connection to take account of normal

movement of the heater.

Warning

When completing the final gas connection to the heater do not

place undue strain on the gas pipe work of the heater.

4.5 Electrical Connections

All units are fully prewired and only require final connections

for the incoming mains supply and fitment of the MC100. The

control is shipped inside the heater burner compartment. Pass

the connection cable through the hole in the front door, fit the

control onto the outside of the door and connent the cable to

the pcb inside the heater. If a MC100 or Powrtrol are not being

used, complete the control circuit (230V) via a room thermostat,

time clock etc.

All units must be earthed. The electrical supply must be run to

a point adjacent to the heater and be suitably terminated to

provide an isolation point that will prevent remote activation

of the unit during servicing. Reference must be made to Table

(Page 3)

to ascertain the electrical loading of the unit(s) being

installed so that cables of adequate cross-sectional area are used

for the electrical installation. The length of the conductors

between the cord anchorage and the terminals must be such that

the current carrying conductors become taut before the earth

conductor if the cable or cord slips out of the cord anchorage.

All external controls must be of an approved type.

See the wiring diagram accompanying these instructions.

Notes for all systems.

Final overall length of adjustable disconnection piece must be between 360 - 415mm.

ii)

45° offsets may be used if required. Each set is equivalent to 0.5m of flue length.

iii) Where VPC heaters are used in clean environments it is permissible to take the combustion air directly from the heated space. The supplied

mesh intake plate, must be fitted to the combustion air inlet on the rear of the heater.

Fig 2a Exhaust only system - horizontal

Fig 3a Individual system - horizontal

Fig 3b Individual system - vertical

6m maximum

Terminal

Lengths

Adjustable

lengths

Single to twin

adaptor

Flashing

Flue socket

Combustion air

socket

Condensate drain

length

Fig 2b Exhaust only system - vertical

12m maximum

Terminal

Lengths

Adjustable

length

Flashing

F l u e

socket

Combustion air entry

(fitted with inlet grille)

Condensate drain

length

Terminal

Lengths

Adjustable

length

F l u e

outlet

Combustion air entry

(fitted with inlet grille)

12m maximum

Terminal

Lengths

Adjustable

length

Single to twin

adaptor

Flue socket

Combustion

air duct

6m maximum

Combustion

air socket

6. Commissioning & Testing
6.1 Electrical Installation

Checks to ensure electrical safety must be carried out by a

qualified person.

6.2 Gas Installation

The whole of the gas installation, including the meter, should

be inspected and tested for soundness and purged in accordance

with the recommendations of IGE/UP/1 (Edition 2) or

IGE/UP/2A as appropriate.

6.3 First Start Sequence

Follow the sequence below before lighting the heater(s) for the

first time.

a) Ensure that the gas supply to the unit is turned OFF.

b) Turn on the electrical supply to the heater and set up the

controls in accordance with their instructions.

Note:The igntion sequence may start during this process

but the heater will not light, as the gas supply is turned off,

and the internal burner control will go to lockout. The lockout

indicator on the external control will be illuminated.

c) Ensure that the controls are not calling for heat i.e. the

thermostat is at minimum or the clock control is set to an

OFF period or the function switch is set to OFF.

d) Check that all warm air delivery outlets are open.

e) If necessary reset the internal control from lockout by

pressing the reset button on the external control for 3 seconds.

f) Check that the overheat reset button has not operated.

g) Ensure that the Summer/Winter switch is in the Winter

position.

h) Turn ON the gas supply.

6.4 Lighting the Air Heater

NOTES:

1. On initial lighting of the heater(s), it may take some time to

purge the internal pipework of air.

IMPORTANT:

The internal pipework of the appliance has been tested for

soundness before leaving the factory. After establishing the

main burners test round the gas inlet connection using a leak

detection fluid e.g. soap solution.

6.4.1 All Models

1. Adjust the controls to call for heat and the ignition sequence

will commence. After a delay of approximately 45 seconds the

ignition spark will be generated and the main gas valves

energized. The burners will then light followed in 15 - 30seconds

by the main air fan.

2. If the burners fail to light the control box will attempt two

further ignition tries before going to lockout and the lockout

light on the internal pcb will be illuminated. To restart the

ignition sequence depress the reset button adjacent to the lockout

light for at least 3 seconds.

SHUT OFF

Set the clock control to OFF or set the room thermostat to MIN.

6.5 Adjustments

6.5.1 Burner Gas Pressure

This is set for the required heat input before despatch. In the

case of Hi/Lo and Modulating units both high and low pressures

are set. Pressures should be checked in the following manner.

Fig 5 Controls Layout

Main Gas Valve

Burner Manifold

(Cover removed

for clarity)

Exhaust Fan

Rectification

Electrode

Main control panel

Exhaust Fan airflow

proving pressure switch

Fan/Limit Thermostat

Flue outlet and

combustion air inlet

(alternative positions on top of unit)

Ignition

Electrode

(Behind gas

valve)

Fig 8 High/Low and Modulating Head

Low pressure
setting screw

Valve stem

Valve body

Locking spring
(Modulating Head)

Locking spring
(Hi/Low Head)

Locknut

Spring

6.6.1.1 Standard Units

1. Set external controls to ensure that the main burner is off.

Open the access door. Connect a pressure gauge to the burner

pressure test point on the multifunctional control.

2. Set external controls so as to turn on the main burner. Compare

the measured burner gas pressure to that stated on the data plate.

If necessary adjust the burner gas pressure by turning the

regulator screw anticlockwise to decrease the pressure, or

clockwise to increase the pressure.

3. In addition it is advisable to check the gas rate using the gas

meter dial pointer. Ensure that no other appliances supplied

through the meter are in operation.

If required, after checking or setting the burner pressures, the

CO2 content in the flue gases can be checked by sampling in

the first section of flue fitted to the flue outlet of the unit.

Nominal CO2 values are 8-9%.

5. Turn off the main burner as in 6.5.1. and disconnect the

pressure gauge and replace the sealing screw. Turn on the main

burner as above and test for gas soundness around pressure test

joint using a leak detection fluid e.g. soap solution.

6.6.1.2 High/Lo and Modulating Heads

1. Set external controls to ensure that the main burner is off.

Open the access panel. Connect a pressure gauge to the burner

pressure test point on the multifunctional control.

2. Set external controls so as to turn on the main burner and

maintain high fire. Compare the measured burner gas pressure

to that stated on the data plate. In addition it is advisable to

check the gas rate using the gas meter dial pointer. Ensure that

no other appliances supplied through the meter are in operation.

3. Repeat 2 above with external controls set to maintain low

fire.

4. If it is necessary to adjust the high pressure setting then

proceed from step i). If it is only necessary to adjust the low

fire pressure setting proceed from step vii).

i) Set external controls to turn main burner OFF.

ii) Pull back the clip D retaining the actuator coil to its mounting

stem and remove the coil.

iii) Set external controls to turn main burner ON.

iv) Screw adjustment screw A fully clockwise.

v) Release the M13 locknut E that secures the actuator stem B

into the mfc governor pack and turn the actuator stem to set the

HIGH FIRE pressure

(clockwise to increase pressure).

vi) Tighten the locknut without further turning the actuator

stem.

vii) Unscrew adjustment screw A to set the LOW FIRE pressure

(anti clockwise to decrease pressure.

viii) Set external controls to turn burner OFF and replace valve

body C onto the valve stem ensuring that it clips into position.

5. Turn off the main burner as in 6.5.1 disconnect the pressure

gauge and replace the sealing screw. Turn on the main burner

as in 6.5.1 and test for gas soundness around pressure test joint

using a leak detection fluid. Replace access panel.

6.6.2 Air Heater Controls

1. Close the gas service tap and ensure that the gas valve is

heard to close within 1 second and that the lockout light is

illuminated. Note that the heater will attempt three reignitions

before going to lockout. Open the gas service tap and reset the

unit from lockout.

2. Check that the room thermostat and all automatic controls

are operating satisfactorily.

6.7 Handing over the Air Heater

Hand the Users Instructions to the user or purchaser for retention

and instruct in the efficient and safe operation of the air heater

and associated controls.

Adjust the automatic controls to those values required by the

User.

Finally, advise the user or purchaser that, for continued efficient

and safe operation of the air heater, it is important that servicing

is carried out annually.

In the event that the premises are not yet occupied turn off the

gas and electricity supplies and leave instructional literature

adjacent to gas meter.

7. Servicing

WARNING:

Always switch off and disconnect electricity

supply and close the gas service valve before carrying out any

servicing work or replacement of failed components.

NOTE:

If a suspended air heater is to be serviced do not lean ladders

against the heater. Ensure that an access tower or equivalent is

used.

7.1 General

Full maintenance should be undertaken not less than once per

year by a qualified person. After any servicing work has been

complete or any component replaced the air heater(s) must be

fully commissioned and tested for soundness as described in

Section 6.

7.2 Main Burner Assembly Removal

1. Ensure that the gas service valve is turned OFF and then

unscrew the union nut situated immediately down stream of it.

2. Disconnect the spark and rectification leads from the pcb

and remove the electrical plug connections from the top of the

gas control valve assembly.

3. If required remove the manifold by first removing the front

heat shield and then removing the four screws securing the

manifold to the burner assembly.

4. Remove the two screws that secure the top of the burner

assembly to the bulkhead and lift out burner assembly

5. Using a stiff brush, not a wire brush, brush the burners to

Governor adjustment screw

under cover cap

(Honeywell VR4605A

B1027)

Governor adjustment screw

under cover cap

(Honeywell

VR425AB1007)

Fig 7

Fig 6

dislodge accumulated deposits. Inspect the burners both internally

and externally to ensure that they are clean. Examine the injectors

and if damaged or deteriorated, replace with new ones of the

correct size and marking. If deemed necessary, clean the injectors.

Do not broach out with wire.

6. Reassemble the injectors, manifold and burners in reverse

order to that above.

7.3 Ignition and Rectification Electrodes

1. Inspect the electrodes, making sure that they are in a sound

and clean condition. In particular check that the ignition electrode

is clean and undamaged. Check that the spark gap is 2.5mm.

7.4 Heat Exchanger

Whilst the main burner assemblies are removed from the unit

check that the primary sections that the burners fire into are

clean.

7.5 Main Fan Assembly

1. Inspect the fan blades to see that they are not damaged and

that there is no excessive build up of deposits that could give

rise to an imbalance.

7.6 Replacement of Faulty Components

7.6.1 Multifunctional Control

1. Remove the electrical plug connections from the top of the

gas control valve assembly

2. Release the flanged connections at the inlet and outlet of the

multifunctional control and remove the multifunctional control.

3. Reconnect the new valve in the reverse order to that above

ensuring that the valve is correctly orientated. Renew the sealing

'O' rings if necessary.

7.6.2 Burners

1. Remove the burner assembly as previously described in

Section 7.2.

2. Remove the end plates of the burner assembly and the central

burner support plate.

3. Exchange burners as required and reassemble components

in reverse order.

4. Re-commission the appliance as described in Section 6.

7.6.3 Electrode Assemblies

1. Disconnect the electrode leads from the pcb terminal as

appropriate.

2. Remove the screw securing the electrode assembly to the

burner assembly side plate and withdraw the assembly.

3. Fit replacement and reassemble in reverse order. Check that

the spark gap is 2.5mm (See Fig. 9).

7.6.4 Limit Thermostat -

Honeywell L4064N

1. Release the single screw securing the fan and limit thermostat

cover and remove cover by pulling forward.

2. Release wiring from clamp terminals by pushing a small

screwdriver into the clamp release holes adjacent to the clamps.

3. Remove the 2 screws securing the thermostat to the heater

panel and withdraw thermostat.

4. Reassemble new unit in reverse order referring to the heater

wiring diagram to ensure correct wiring location.

Important:

A replacement fan/limit thermostat will have a

brass link between the bottom fan terminal and the bottom limit

terminal (situated in the slot between the two terminals). This

MUST

be removed, by breaking the link off using a pair of thin

nose pliers, before the replacement thermostat is installed.

NB. Ensure that the thermostats are set correctly before fitment

Limit Thermostat settings:-

VPC 30, 52

90°C

VPC 80

80°C

VPC 110, 130

120°C

Note:

The new L4064N may be supplied with the limit

temperature mechanically limited to less than the setting required.

To release the mechanical limit push a pointed object into the

small hole at the top of the dial. At the same time prevent the

dial from rotating and push the limit temperature adjuster around

to the required setting.

7.6.5 Exhaust Fan

1. Disconnect the flexible pipe from the fan outlet.

2. Disconnect fan electrical connections from the terminals on the pcb.

3. Remove the fan and fan mounting plate from the bulkhead

(4 screws).

4. Fit replacement exhaust fan, using new gaskets, and reassemble

in reverse order.

7.6.6 Air Pressure Switch

1. Disconnect electrical connections.

2. Pull off the sensing tube from the air pressure switch.

3. Remove the screws fixing the air pressure switch and remove

switch.

4. Fit replacement in reverse order refitting the sensing tube to

the negative (- or L) tapping on the pressure switch.

7.6.7 Printed Circuit Board (pcb)

1. Disconnect all electrical connections.

2. Release the through hole clips securing the pcb and remove

pcb.

3. Fit replacement in reverse order.

7.6.8 Main Air Fan(s)

1. Remove the lower side panels.

2. Disconnect the fan motor electrical lead from the controls.

3. Remove the screws securing the fan to the fan shroud and

slide fan out. Note that the fans on the VPC110 and 135 are

removed through the rear of the heater.

4. Fit replacement in reverse order.

2.5mm

Fig 9 Ignition Electrode Spark Gap

DO NOT

ROT

E - HOLD

DIAL

WHEN SETTING POINTERS

20 40 60 8

FAN L

OFF ON

C°

Limit Setpoint

Adjustment

Fan Circuit

Limit Circuit

Limit Reset

Fan ON

Override

Set Point Dial

Brass Link Location

Mechanical Limiter

Release Point

Mechanical limiter

Fan OFF Setpoint

Adjustment

Limit Circuit

Fan Circuit

Fan ON Setpoint

Adjustment

Fig 10 Thermostat Fan / Limit - Honeywell L4064N

8. Fault Finding Flow Chart

Gas & Electrical

supplies present at heater

Yes

Turn supplies on

Check fuses/connections

Lock out light on

after 3 secs.

Exhaust fan runs

Faulty gas valve.

Check/replace

resistor on PCB

between gas valve

2 live & neutral

230V at Heat terminal on PCB

Check control circuit (Time clock/thermostats) calling for heat

Yes

Voltage at limit stat 1 on PCB

Check Fuse 1

Faulty PCB

Voltage at limit stat 2 on PCB

Check limit stats, reset manual stat. Check connections

Yes

230V to air pressure

switch common

Faulty PCB

Yes

230V to air pressure

switch N.O.

230V to exhaust

fan

Pressure switch sensing

pressure. Adjust set

point/replace

Replace exhaust

fan

Yes

230V to air pressure

switch N.O.

Yes

Check pressure sensing tube. Adjust pressure switch set point.

Change pressure switch

Yes

Gas valve opens

230V to gas valve

Faulty PCB

Ignition sparks

Check/replace rectification probe. Faulty PCB

Yes

Faulty gas valve

Burners light

Check gas pressures. Replace gas valve

Check spark

probe/lead.

Faulty PCB

Burners remain

alight

3 ignition attempts then goes to lock out.

Main fan runs

230V at main

fan motor

Check connections. Check contactor

Reset overload. Faulty PCB

Replace motor or fan/motor assembly

Yes

Heater working correctly

Exhaust fan runs

Check fuse 2

Replace

Failed

START

Yes

Failed

Replace

ITEM

USAGE

PART #

MFC - Honeywell VR4605AB1027

30-80

145035204

MFC - Honeywell VR425AB1007

110, 130

141378715

Ignition Electrode (small)

30-80

142423002

Ignition Electrode (large)

110, 130

142423004

Rectification Electrode

30- 130

142423003

Burner - Bray P51 AB 19001

30-80

142400240

Burner - Bray P51 AB 19002

110, 130

142400241

10. Short List of Parts

Only originally specified parts may be fitted as service replacements.

Please refer to Powrmatic Ltd for any parts not detailed in the listing below.

Hi/Lo Governor Head - Anglo Nordic MD20003

30-130 -/HL

142466410

Modulating Governor Head - Anglo Nordic MD1003/MD

30-130 -/MOD

142466421

Amplifier board - Johnsons PIB-24

30-130 -/MOD

142400304

Exhaust Fan - Sifan WFFB 0223-006

30, 52

140210499

Exhaust Fan - Torin 077445

80-130

140201505

Dungs LGW 3A2

30, 52

146522174

Dungs LGW 10A2

80-130

142961107

Contactor - Danfoss CI 12

All

143000610

Main PCB

All

142403610/3

9. Wiring Diagram

See the wiring diagram supplied with the heater

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

HEATING DIVISION

Hort Bridge

Ilminster, Somerset TA19 9PS

Tel: 01460 53535 Fax: 01460 52341

BSI Registered Firm

FM 414

Ind. & Comm. Air Heaters;

Air Moving Equipment;

Natural Smoke & Heat

Ventilators;

Powered Supply & Extract

Fans & Systems.

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