Clarke Devil 900DV, 6920175 User guide

GAS HEATERS

MODEL NOS: DEVIL 900DV, 1600DV & 2100DV

PART NOS: 6920175, 6920191 & 6920196

USER INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0722 - Rev 1

INTRODUCTION

Thank you for purchasing this CLARKE Gas Powered Heater.

Before attempting to use this product, please read this manual thoroughly and follow
the instructions carefully. In doing so you will ensure the safety of yourself and that of
others around you, and you can look forward to your purchase giving you long and
satisfactory service.

FUNCTION AND OPERATING PARAMETERS

This is gas powered heater. It’s intended use is for drying and the warming of
commercial/industrial buildings where adequate ventilation is provided.

• It must be operated as prescribed in the operating manual.

• Is not intended to be used for domestic use or for the heating of habitable areas.

• Is not intended to be used to reach and maintain a certain level of human
thermal comfort within an enclosed space in which the heater is situated.

• Is not intended to be used in enclosed areas with restricted ventilation.

• Is not for use in areas with high levels of fluctuating drafts.

• Is not intended for warming animals or live stock.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12 months from
the date of purchase. Please keep your receipt which will be required as proof of
purchase.

This guarantee is invalid if the product is found to have been abused or tampered with
in any way, or not used for the purpose for which it was intended.

Faulty goods should be returned to their place of purchase, no product can be
returned to us without prior permission.

This guarantee does not effect your statutory rights.

UNPACKING

When unpacking, check the heater for possible shipping damage. Should any damage
be apparent, please notify your Clarke dealer immediately.

Your heater is fully assembled,- only the electrical and gas supplies need connecting.
Retain any plastic cover caps (attached to the inlet connector and hose/regulator
assembly) for future storage.

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SAFETY INFORMATION

WARNING: LACK OF VENTILATION CAN CAUSE CARBON MONOXIDE
POISONING.

WARNING: CARBON MONOXIDE POISONING CAN KILL.

Signs of Carbon Monoxide poisoning are headaches, dizziness and/or nausea. Should
anyone show these signs, they must GET FRESH AIR IMMEDIATELY. Turn off the heater and
have it serviced before using again.

Pregnant women, persons with a heart or lung condition, anaemia or under the
influence of alcohol, or those at high altitude, are more likely to be effected by Carbon
Monoxide.

Read, and make sure you fully understand the following precautions and the hazards
associated with this type of heater.

• Use only liquid propane gas with this heater.

• Ensure the Propane gas bottle, gas hose and electric cable, are positioned
behind the unit, well away from the heat.

• Ensure gas hose and regulator connections are gastight and the hose is not
kinked.

• Never use the heater where flammable vapours or if a high dust content is
present in the air.

• Only use with the voltage specified and ensure the heater is properly earthed.

• Use only in well ventilated areas. Provide ventilation of at least 3 square feet of
fresh air for every 100,000 BTU/hr of rating.

• Always allow the working clearances around the heater as stated on page 7.

• Keep the heater as far as practical from propane tanks and never point the
heater directly at any propane tank.

• Stand the heater on a stable, level surface whilst hot or operating. If the heater
should overturn, a fire could occur.

• Keep children and animals away from heater at all times.

• Use heater in accordance with all fire regulations.

• Never use heater for domestic heating in living or sleeping areas.

• Never leave a heater plugged in without adult supervision if children or animals
are likely to be present.

• Never move, handle, replenish the gas supply or service the heater when it is hot,
operating or plugged in.

• Never attach the heater to any duct work, or impede air flow into or out of the
heater.

• Disconnect the heater from the power supply when not in use.

• Use ONLY the factory pre-set regulator supplied with the heater.

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• If the heater works for long periods at maximum capacity, be aware that it is
possible for ice to form on the gas cylinder due to excessive evaporation.

• Never direct hot air towards the cylinder in order to de-ice.

• Never use in wet areas, basements or below ground level. Propane gas is heavier
than air and will sink to the lowest possible level.

• Always ensure the heater is correctly maintained in accordance with this manual.

SAFETY SYMBOLS

Please read all of the safety and operating instructions carefully before using this
product. The following safety symbols may be found on the product

General hazard warning Danger-Hot Surfaces.

.

Always read the manual
before use

.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the obligation to
deal with the WEEE in accordance with the WEEE regulations in relation to the
treatment, recycling & recovery and environmentally sound disposal of the
WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing Waste
Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.

CARBON MONOXIDE

WARNING: LACK OF AIRFLOW CAN CAUSE CARBON MONOXIDE
POISONING.

WARNING: CARBON MONOXIDE POISONING CAN KILL.

WE RECOMMEND THAT YOU USE A CARBON MONOXIDE
DETECTOR, AVAILABLE FROM YOUR CLARKE DEALER

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WHAT ARE THE SIGNS

The 6 symptoms to look out for:

• Headaches • Breathlessness

• Dizziness • Collapse

• Nausea • Loss of consciousness

The following groups of people are more likely to be effected by Carbon Monoxide.

1. Pregnant women,

2. Persons with a heart or lung condition, anaemia

3. People under the influence of alcohol,

4. Those living/working at high altitude

WHAT TO DO IF YOU SUSPECT CO POISONING

• Get fresh air immediately. Open doors and windows, switch off the heater and
leave the area.

• See your doctor immediately or go to hospital - let them know that you suspect
CO poisoning. They can do a blood or breath test to check.

• Do not use the heater until it has been serviced.

ELECTRICAL CONNECTIONS

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an
approved 13 amp BS 1363 plug or a suitably fused isolator switch.

The heater may also be connected to a 110V supply through a suitably approved plug.

TO CHANGE THE VOLTAGE

1. Remove the two screws shown.

2. Rotate the cover so that the voltage
you want is at the top (230V or 110V).

3. Replace the cover and screws.

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4. Make sure that the plug is suitable for the voltage selected and replace it if

necessary

.

WARNING: THIS APPLIANCE MUST BE EARTHED.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

As the colours of the flexible cable of this appliance may not correspond with the
coloured markings identifying terminals in your plug proceed as follows:

• Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth

symbol.

• Connect BROWN cord to terminal marked with a letter “L”

• Connect BLUE cord to terminal marked with a letter “N”

If this appliance is fitted with a plug which is moulded onto the electric cable (i.e. non­rewirable) please note:

1. The plug must be thrown away if it is cut from the electric cable. There is a danger of
electric shock if it is subsequently inserted into a socket outlet.

2. Never use the plug without the fuse cover fitted.

3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).

4. Replacement fuse covers can be obtained from your local dealer or most electrical
stockists.

5. The fuse in the plug must be replaced with one of the same rating (13 amps) and this
replacement must be ASTA approved to BS1362.

We strongly recommend that this machine is connected to the mains supply through a
Residual Current Device (RCD).

If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.

PROPANE GAS SUPPLY

These heaters are designed for use with PROPANE GAS ONLY. Gas cylinders are not
supplied, but are readily available from builders merchants or gas suppliers etc.

This range of portable, direct fired gas heaters is designed to BS 4096 for industrial
applications to give safe, efficient and reliable operation.

As with all mechanical equipment, optimum performance will only be achieved if the
correct operation and servicing procedures are followed

.

WARNING: PROPANE GAS CYLINDERS MUST BE USED AND STORED IN
ACCORDANCE WITH THE HIGHLY FLAMMABLE LIQUIDS AND LIQUEFIED
PETROLEUM GASES REGULATIONS 1972.

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GAS CONNECTION

Connect the free end of the gas hose to the gas inlet connection on the heater and
tighten to ensure there are no gas leaks. Before attaching the regulator to the gas
cylinder, ensure the mating parts are free from grease and dirt and are undamaged.

Fit the regulator to the cylinder, tightening
the thread as tight as possible with a
propane spanner, noting that the threads
are LEFT HANDED. To check for leaks, use
soapy water or liquid soap applied to
each of the connections. Any bubbles
formed indicate a leak. Correct all leaks
immediately.

IMPORTANT: The gas hose and cylinder
must ALWAYS be located well behind the
heater.

In order to reduce the risk of icing up
when operating at long periods at
maximum capacity, you should use a
larger capacity gas bottle, or two/three
bottles in parallel, as shown in Fig 2.

• The ‘Tee’ piece and ‘pigtails’ are

readily available from your builders
merchants or gas supplier.

CHANGING GAS BOTTLES

1. Turn off the heater and disconnect
from the electrical supply.

2. Close the gas valve on the bottle and unscrew the regulator, (left hand thread).

3. Ensure the replacement bottle screw threads and gas orifice is perfectly clean
before screwing in the regulator valve tightly.

4. Check to ensure there are no leaks using soapy water and when satisfied, plug in to
the electrical supply and restart the heater.

OPERATING SPACE AND AIR SUPPLY

MINIMUM FRESH AIR OPENING REQUIREMENTS

As a general rule of thumb, an opening of 1in2 per 1000 Btu/hr is a minimum
requirement.

These heaters are specified as requiring a minimum ventilation of 3 sq/ ft per 100,000BTU/
hr.

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OPERATING SPACE

Do not obstruct the air intake to the heater and allow the following clearances from
combustible surfaces.

Outlet: 8 feet (2.4 m)

Sides: 2 feet (0.6 m)

Top: 6 feet (1.8 m)

Rear: 2 feet (0.6 m)

Keep the heater as far as practical from propane tanks and never point the heater
directly at any propane tank.

PRINCIPLE OF OPERATION

Understanding the basic operation of the heater will reinforce the need to maintain the
unit in top condition at all times, whilst always observing the safety precautions.

The heater comprises four basic systems:

1. The gas system.

2. The air system.

3. The ignition system.

4. The safety control system

GAS SYSTEM

The gas supply to the machine is by means of a high pressure hose, connected to an
LPG (Liquid Propane Gas) cylinder, via a pressure regulator.

When the mains supply is switched on, the Safety Shut-off valve solenoid is energised,
allowing the gas to flow to the Flame Failure valve, and when the failure valve override
knob is depressed, gas flows to the burner head.

AIR SYSTEM

An axial fan, which is energised when switching on, provides the air flow through the
combustion chamber to provide a stream of hot air from the heater.

IGNITION SYSTEM

Ignition is automatic with this heater as soon as the gas valve button is depressed, with a
continuous spark from the spark plug igniting the gas. As the thermocouple heats up, a
low voltage is fed to the Flame Failure valve, causing the valve to open, so that after a
few seconds, the gas valve button may be released and the flame is established.

SAFETY CONTROL SYSTEM

Should the flame extinguish for any reason, the thermocouple will quickly cool, causing
the Flame Failure valve to close, shutting off the gas supply.

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Similarly, should there be a power failure, causing the fan motor to stop, the Safety Shut­Off valve solenoid will become de-energised, and therefore shut off the gas supply..

Additionally, the machine is equipped with thermal overload protection, which will
intervene should the unit overheat, shutting off the electrical supply.

STARTING PROCEDURE

WARNING: BEFORE STARTING THE HEATER, YOU MUST ENSURE THAT THE
MINIMUM VENTILATION REQUIREMENTS ARE OBSERVED TO AVOID THE
RISK OF CARBON MONOXIDE POISONING.

1. Ensure there is sufficient gas and that it is correctly connected.

2. Open the supply valve on the gas
cylinder, and fully open the regulator
valve adjacent to the gas inlet pipe.

3. Plug the heater in to a suitable power
supply.

4. Set the flame intensity control valve
(B), to a low setting,

5. Set the fan switch (A) to the ON (I)
position. Confirm the fan operates.

6. Hold in the gas valve button (C), until
the thermocouple is energised and
the heater ignites.

7. If the heater fails to ignite, there may be air in the hose so keep the fuel valve open
and wait for about 15 seconds. Wait 30 seconds for unburned fuel to exit the heater.
Repeat the step above.

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8. When the burner remains lit, set the heater at the required level by turning the flame
intensity control valve counter-clockwise. If the burner goes out, turn off the gas. Turn
the gas valve fully clockwise to its lowest position. Check the fuel supply. If adequate
fuel is available, re-start the heater from step 1.

Should the flame extinguish when the ignition button is released, wait for 1 minute,
before repeating the operation.

• Turning the flame intensity control valve anti-clockwise will increase the gas

supply and therefore the output, clockwise to decrease.

If ignition is difficult or irregular, ensure the fan is operating and that the air inlet and
outlet are completely clear. Also ensure that the electrode gap is correct, and that the
electrode is clean (see Maintenance).

Should the thermal overload protection feature operate and the spark plug is seen to
be operating, shut off the gas supply and allow the unit to cool for at least 10 minutes
with the fan running, before attempting to relight the burner.

Should the flame safety valve operate, the heater may be restarted once the cause of
the problem has been found and rectified.

SHUT-DOWN PROCEDURE

1. Turn off the gas at the propane cylinder valve(s).

2. Let the heater run while any gas left in the supply hoses is burnt off.

3. Allow the fan to run for 2 - 3 minutes with the burner off, in order to allow the casing
to cool down and the fan to disperse any residual gas.

4. Switch off the fan and unplug from the electrical supply.

5. Disconnect the gas supply.

MAINTENANCE

CAUTION: DISCONNECT THE HEATER FROM THE PROPANE SUPPLY
CYLINDER(S)

WARNING: BEFORE CARRYING OUT ANY ADJUSTMENT OR
MAINTENANCE, ENSURE THE HEATER IS SWITCHED OFF, DISCONNECTED
FROM THE MAINS AND GAS SUPPLY, AND HAS BEEN GIVEN ADEQUATE
TIME TO COOL DOWN.

It is essential that the heater is correctly maintained and kept in top condition at all
times.

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All models are similar, in that access to the control components is gained by removing
the access panel under the base of the heater which is secured by screws around the
edge.

MONTHLY (WHEN IN CONSTANT USE)

Check the spark plug for cleanliness and correct operation. Have the gap re-set to no
more than 5mm by your Clarke service engineer.

Check the condition of the gas hose. If there are any signs of deterioration, it should be
renewed using only a Clarke original spare part.

Ensure that all connections are clean and secure.

When necessary, clean the fan and the inside of the heater thoroughly.

The use of parts other than genuine Clarke replacement parts may result in safety
hazards or decreased performance, and will invalidate your warranty.

STORAGE

1. Store the propane gas cylinders in a safe manner outdoors and keep them below

o

100

F (37 oC).

2. Place protective bags over fittings & connectors and store in a clean, dry place.

3. Fit the plastic cover caps which were removed when unpacking, over the
connections they covered when received.

4. When removing from storage, always check inside of heater for debris/foreign
objects before returning to use. Do not store the hose/regulator inside the
combustion chamber.

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TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Motor does not start. No power. Check power supply, power

cable and fuse, and replace
if necessary.

Faulty motor/capacitor. Fan
blades bent.

Lock out of appliance due to
overheating. Thermal cut-out in
operation.

Spark plug does not
spark.

Heater will not ignite Connection/installation

Heater stops during
operation.

Gap incorrect, faulty
connection

incorrect.

No spark at spark plug due to
loose HT lead or PCB fault.

Excessive or insufficient gas
supply.

Check & replace if
necessary.

Identify cause of over­heating. Wait for 5 mins and
restart. If condition persists,
contact your Clarke dealer
for advice.

Clean and reset gap if
necessary or replace.

Check that installation
instructions are followed.

Check spark plug wire.
Tighten or re-attach if loose. If
condition persists, contact
your Clarke dealer for
advice.

Check pressure regulator &
replace if necessary.

Check that fan motor works
properly.

Check, and use a larger
cylinder, or two or more in
parallel.

Check there are no
obstructions to air flow.
Check ventilation is
adequate. See also ‘Motor
does not Start’.

No gas flow to the
burner.

Cylinder gas tap closed. Open the gas tap.

Cylinder is empty. Replace cylinder.

Nozzle is obstructed. Remove nozzle & clean.

Gas leaks from supply hose or
from tap.

Use soapy water to find the
leak and repair.

PROBLEM CAUSE REMEDY

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Burner starts but stops as
the gas valve button is
released.

Thermocouple is not warm
enough or is faulty.

Weak gas supply. Increase flame intensity

Repeat the starting
operation, keeping the gas
valve button depressed for
longer.

control valve setting.

SPECIFICATIONS

Model Number 900DV 1600DV 2100DV

Dimensions (L x W x H) mm 500x215x370 500x215x370 640x220x385

Weight 6.65 kg 6.7 kg 8.6 kg

Fuse Rating 13A 13A 13A

Operating Voltage 230V/50Hz

1ph/110V

50Hz

Rated Input Power 100W 110W 130 W

Rated Input 110V - 1.5A

220V - 0.75A

Gas Consumption (kg/hr) 1.16-1.79 1.59-2.63 3.0-3.86

Air Flow (m3/hr) 535 580 690

Gas Pressure (max) 300mBar 300mBar 300mBar

Min Heat Output (kWbtu) 16.1/55,000 22/75,000 35/120,000

Max Heat Output (kW/btu 24.9/85000 36.6/125,000 50/170,000

Please note that the details and specifications contained herein are correct at the time
of going to print. However CLARKE International reserve the right to change
specifications at any time without prior notice. Always consult the heater’s data plate.

230V/50Hz

1ph/110V

50Hz

110V - 1.5A

220V - 0.75A

230V/50Hz

1ph/110V

50Hz

110V - 1.5A

220V - 0.75A

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PARTS DIAGRAM - DEVIL 900DV/1600DV

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PARTS LIST DEVIL - 900DV/1600DV

No Description No Description

1 Outer Shell 20 Fuel Tube Assembly

2 Handle Mounting clips 21 Extension Fitting

3 Handle 22 Control Valve Assembly Nut

4 Middle Cylinder 23 Control Valve Assembly

5 Front Guard 24 Male Fitting Connector

6 Orifice Assembly 25 Solenoid Valve Assembly

7 Flame Holder Assembly 26 Solenoid Valve Assembly Nut

8 High Limit Switch Bracket 27 Flame Intensity Control Knob

9 High Limit Switch 28 Control Box

10 Spark Plug Nut 29 Dual Voltage Switch

11 Spark Plug Washer 30 Dual Voltage Switch Cover

12 Spark Plug 31 Power Switch

13 Fan 32 Strain Relief Bush

14 Motor Assembly 33 Power Cable Assembly

15 Inlet Grille 34 Ignition Circuit Board

16 Thermocouple Bracket 35 Hose/Regulator Assembly

17 Thermocouple 36 Access Panel

18 Orifice Nut 37 Rubber Foot

19 Elbow Fitting

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PARTS DIAGRAM - DEVIL 2100DV

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PARTS LIST - DEVIL 2100DV

No Description No Description

1 Outer Shell 21 Elbow Fitting

2 Handle Mounting Clips 22 Fuel Tube Assembly

3 Handle 23 Extension Fitting

4 Middle Cylinder 24 Control Valve Assembly Nut

5 Front Guard 25 Control Valve Assembly

6 Orifice Assembly 26 Male Connector Fitting

7 Flame Holder Assembly 27 Solenoid Valve Assembly

8 High Limit Switch Bracket 28 Solenoid Valve Assembly Nut

9 High Limit Switch 29 Flame Intensity Control Knob

10 Spark Plug Nut 30 Control Box

11 Spark Plug Washer 31 Dual Voltage Switch

12 Spark Plug 32 Dual Voltage Switch Cover

13 Fan 33 Power Switch

14 Motor Assembly 34 Strain Relief Bush

15 Motor Mounting Bracket 35 Power Cable Assembly

16 Bracket 36 Ignition Circuit Board

17 Inlet Grille 37 Hose/Regulator Assembly

18 Thermocouple Bracket 38 Access Panel

19 Thermocouple 39 Rubber Foot

20 Orifice Nut

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WIRING DIAGRAM

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DECLARATION OF CONFORMITY -

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