Powrmatic VPC Series, VPC52, VPC30, VPC110, VPC80 User, Installation & Servicing Manual

VPC Gas Cabinet Heater Range

Industrial & Commercial Heating Systems

Doc Ref: M202 Issue 5.5 Aug 2018

User, Installation & Servicing Manual

www.powrmatic.co.uk

+44 (0) 1460 53535

info@powrmatic.co.uk

Certificate of Guarantee

Dear Customer

This is to certify that this heater is guaranteed for two years parts and one year labour from the date of original commissioning. The heater must be commissioned within 4 weeks of installation.

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. As much detail as possible on the fault.

3. Your supplier, or installer, will then contact Powrmatic to make a guarantee claim on your behalf.

Conditions of Guarantee

1. The heater must have been installed by a competent recognised installer, and in accordance with the manufacturer’s instructions, building regulations and local regulations.

2. The heater has been professionally commissioned, within 4 weeks of installation, and a copy of the commissioning sheet returned to Powrmatic.

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

4. The heater has been used in accordance with the manufacturer’s instructions.

5. The correct speciﬁcation fuel has been used.

6. No unauthorised repairs of modiﬁcations have been made. Powrmatic ‘General Conditions of Sales’ have been observed.

7. 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 cost arising from loss of use of the heater, or any event arising there from.

Exclusions

Consumables such as gaskets, ignition electrodes, ﬂame rectiﬁcation electrodes, drive belts, fusible links, control batteries are all excluded from guarantee.

----------------------------------------------------

Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk e-mail: warranty@powrmatic.co.uk

Important: This certicate

must be kept with the appliance

Failure to provide a copy of the commissioning sheet invalidates the heater warranty

Installer Date:________________Signed: _____________________________________Installer

Commissioned Date:________________Signed:_______________________Commissioning Engineer

page no. 2 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Dear Customer - thank you for choosing Powrmatic.

We appreciate you buying one of our high quality products and know that you have made the best choice. By choosing Powrmatic, you are investing in UK manufacturing & its workforce. We pride ourselves by manufacturing products that provide clean, comfortable and safe working environments worldwide together with the personal & professional service and back-up you deserve. If you have any questions or concerns regarding this product, please contact our Technical Support Team by calling 01460 53535.

Users, Installation and Servicing Instructions

CONTENTS

Title Section Contents Page

User Instructions 4

Pre Installation

1.1 Introduction 5 Duties 6 Dimensions 7 Accessories 8

1.2 Technical data 9

1.3 General Requirements 11

1.4 Ventilation Air Requirements 13

Installation

2.1 Fitting the unit 14

2.2 Flue/Combustion Air Duct System 16

2.3 General Identiﬁcation of Electrical Items 18

2.4 Electrical Cable Installation 19

2.5 Wiring Diagrams 20

2.6 Commissioning and Testing 26

2.7 Servicing 30

Additional Documents

3.1 Fault Finding Flow Chart 33

3.2 Short List of Parts 34

3.3 Gas Conversion 36

Appendices Information required for ecodesign (ErP) Directive 2009/125 38

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 3 of 40

User Instructions

If the heater has not been left operational proceed as follows.

A) Checks before lighting the Air Heater

The following preliminary checks should be made before lighting the heater(s)

a) Ensure that the ELECTRICAL supply to the heater is switched OFF. b) Check that all warm air delivery outlets are open. c) Check that the thermostat is set at MAX. d) Check that the clock control is set to an ON period. e) Check that any other controls are calling for heat.

B) Lighting the Air Heater

1. Switch on the electrical supply at the isolator

2. If the Limit indicator light comes on press the limit interlock reset switch inside the heater.

3. The startup sequence will commence. After a short delay the burners will light.

4. If the burners fail to light the control box will automatically restart the ignition sequence. If after 5 attempts at ignition the burners have still failed to light the control box will go to lockout and the amber lockout light inside the heater (or on the low level remote reset, MC200 or Powrtrol RR if ﬁtted) will be illuminated. To restart the ignition sequence depress the reset button on the low level reset for about 1-2 seconds.

D) Description of Operation

Important: The heater must NOT be controlled by switching ON and OFF the main electrical supply to it.

1) Standard Units

The ignition sequence commences each time the external controls e.g. Time clock, room thermostat etc. call for heat. The internal exhaust fan will run and, when suﬃcient combustion airﬂow is proved by the air pressure switch, the ignition spark will be generated, the main gas valve opens and the burners light. The heater fan will automatically start approximately 2 minutes after the burners light. When the external controls are satisﬁed the burners will be turned oﬀ and approximately 2 - 3 minutes later the heater fan will be automatically stopped. If the burners fail to light the control box will make another four attempts at ignition.

2) High / Lo & Modulating Units

When the 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 controls system.

3) Summer / Winter Modes

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.

WARNING: If it is not possible to light the heater after several attempts, contact the installer or local service company.

C) To Shut Down the Air Heater

1) For Short Periods:

Turn the room thermostat to the OFF, or set to it’s lowest setting.

2) For Long Periods:

Complete step 1 above. Wait for 5 minutes and then turn OFF the electrical supply at the isolator.

page no. 4 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

4) Fan and Limit Control

The fan and limit controls are mounted towards the top of the air heater inner bulkhead and are accessed via the front door.

i) Main Air Fan MAN / Auto

When the white button is pushed in the fan will run continuously i.e. not controlled by any external controls e.g. Time clock. When the white button is pulled out the fan will start and stop automatically in conjunction with the burner.

ii) Limit Thermostat

This operates if high temperatures within the heater are detected, the burners are turned oﬀ and a red indicator light inside the heater is illuminated. The fault condition must be identiﬁed and rectiﬁed and the thermostat manually reset. When the unit has cooled push the reset switch on the front of the heater to reset the limit thermostat interlock relay, the red indicator light will go out and the unit is operational again.

Note: The limit thermostat(s) can only be reset once the unit has cooled down. Unless the cause of the fault condition is

readily obvious, for example a power cut whilst the heater was operating, a service engineer should be contacted.

All Powrmatic heaters use gas and electricity to power them, they may also contain moving parts such as pulleys and 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.

E) Maintenance

To maintain eﬃcient, reliable and safe operation of the heater it must serviced by a qualiﬁed person at least annually and preferably at the end of the heating season.

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 at the meter and contact the local gas undertaking immediately.

1.1 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 feature a closed combustion circuit and have an internal exhaust fan, mounted downstream of the heat exchanger, to evacuate the products of combustion and draw in air for combustion. The air heater must be connected to a ﬂue system that is approved by Powrmatic Ltd.

They may be used where the atmosphere inside the premises could be contaminated e.g. Dust, oil mist etc. but the heaters are not airtight and therefore may not be used in areas classiﬁed as hazardous as deﬁned in BS 5345: Part 2 or areas subjected to signiﬁcant negative pressures due to extract systems.

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 qualied 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.

* An approved class of person listed on the gas safe register.

VPC heaters have a centrifugal fan assembly ﬁtted at the base of the heater to circulate the air being heated past the formed tube heat exchanger.

Heaters are ﬁtted as standard with inshot burners, a fully automatic control for ignition, ﬂame sensing, gas supply control and safety functions, an internal exhaust fan, main air fan and fan/limit thermostat.

Options include High/Low or Modulating burner controls, inlet duct connection, outlet duct connection, 90° outlet bend and a full range of modular duct components.

IMPORTANT Service and Maintenance Engineers shall

ensure that replacement items are tted,

adjusted and set in accordance with the data and detail set out in these instructions. If in doubt consult Powrmatic Technical Department.

Gas Safety (Installation & Use) Regulations 1998

It is law that all gas appliances are installed, adjusted and, if necessary, converted by qualied 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.

* An approved class of person listed on the gas safe register.

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 5 of 40

VPC UF / VPC UD

Duties

Model

Output kW 30 52 80 110 130

Input (nett CV) kW 32.6 56.5 87.0 119.5 141.3

Volume m3/s 0.87 1.59 2.34 2.96 3.63

Heads m 3 3 4 4 4

Airflow

Electrics

Fuel

Overall Dims

Install Clearance

Flue

Combustion Air Spigot mm Ø 100 130

Noise Levels dB(A) 60 68 76 72 74

Nett Weight kg 178 248 305 362 410

Throw m 12.0 22.0 21.0 26.0 27.0

Fan Static

Supply

Std Fan

Connection BSP/Rc ¾”

Minimum Inlet Pressure

Consumption

UF Upright Freeblow

Diameter mm Ø 100 130

Max Length

Standard Pa 150 200 225 150 200

Uprated (Refer to Powrmatic)

Standard V/ph/Hz 230/1/50

Optional V/ph/Hz n/a 400/3/50

Motor kW 0.55 1.1 1.4 1 x 1.5 1 x 2.2

Start amp 6.5 8.3 19 28 40

Run amp 4.2 4.2 9.5 9.3 10.7

Nat Gas mbar 17.5

LPG mbar

Nat Gas m3/h 3.45 5.98 9.19 12.64 14.94

LPG m3/h 1.33 2.31 3.55 4.89 5.78

Height mm 2272 2713 2804 2715 2998

Width mm 750 750 750 750 750

Depth mm 1108 1108 1412 1767 1767

Front mm 1000

Blank mm 150

Louvred mm 500

Read mm 500

Flue Only m 12

Room Sealed m 6

30 52 80 110 130

37.0

Notes -

• Fuel consumption and output figures based upon nett calorific values as follows

-Natural gas (G20) nett CV 34.02 MJ/m³

-Propane (G31) nett CV 88.00 MJ/m³

• Heaters have efficiency levels which meet with the minimum heater efficiency requirements of UK Part L Building Regulations

• Air handling data is assessed at room ambient conditions

• Throw figures provide the distance to the point where the terminal velocity degrades to 0.25 m/s

• Overall vertical heater height include heads or extended heads where appropriate

• Standard height heads can be specified where site height is restricted

• Blank and louvred lower side panels are interchangeable

• Noise levels are applicable to standard UF models and are measured 5m from appliance and in free field conditions

• Motor kW, run and start amps apply to standard electrical supply as stated. For optional data contact sales office

• Connection of combustion air duct is not required for ‘flue only’ applications

• It is the responsibility of the installing contractor to ensure that ductwork is correctly sized and balanced when installing ducted units

page no. 6 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Dimensions

J 1

COMBUSTION

AIR INLET

M

J

EXHAUST

AIR OUTLET

Ø D

J 1

ALTERNATIVE FLUE & COMBUSTION AIR

POSITIONS

G

J

K

H

L

M

E

50

H

L

M

C

GAS ENTRY

F

BAB

Model A B C D E F G H J J1 K L M

30 1108 750 1676 100 265 1378 142 237 255 596 207 657 650 2

52 1108 750 2132 100 265 1832 142 237 286 581 256 657 650 2

80 1412 750 2132 130 265 1756 220 237 340 672 308 960 650 3

110 1767 750 2043 130 265 1667 220 237 340 672 308 1315 650 4

130 1767 750 2209 130 265 1835 220 237 400 788 358 1315 650 3

Head

Plan

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 7 of 40

Accessories

Side/Rear Inlet Spigot Side/Rear Filters

660

L

SIDE REAR

50

660

650

50

760

136

660

N

Model 30 52 80 110 130

L 657 960 1315

N 757 1060 1415

Notes -

• All dimensions are outside dimensions

• Vertical units shown.

• Standard filter specification is 10ppi

• Higher specification filters available on request - contact our sales team for more information

• Standard dampers are manual operation - motorised options available

L

SIDE REAR

650

750

660

136

760

Side/Rear Dampers

185

660

L

N

SIDE REAR

650

750

660

185

760

Head Plans

Head Plan 2 Head Plan 3Head Plan 1

page no. 8 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

1.2 Technical Data

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

Minimum Inlet Pressure = 17.5mbar

Injectors

MODEL No. Size (mm)

Marked mbar m/h % °C mbar m/h % °C

Burner

Pressure

VPC30 6 1.94 194 13.8 3.45 8.6 171 4.6 1.90 3.7 125

VPC52 12 1.94 194 10.4 5.98 8.2 17 2 3.0 3.22 3.1 117

VPC80 12 2.54 254 8.1 9.19 8.0 146 2.1 4.44 2.7 91

VPC110 10 3.00 300 10.2 12.64 9.0 180 3.2 6.50 3.2 114

VPC130 12 3.00 300 10.0 14.94 7.2 180 3.6 8.26 3.4 113

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

Minimum Inlet Pressure = 37mbar

Injectors

MODEL No. Size (mm)

Marked mbar m/h % °C mbar m/h % °C

VPC30 6 1.36 136 21.7 1.33 11.0 170 7. 0 0.74 4.6 125

Burner

Pressure

High Fire Low Fire

Gas

Rate

Gas

Rate

Nominal

CO

High Fire Low Fire

Nominal

CO

Nett Flue

Tem p

Nett Flue

Tem p

Burner

Pressure

Burner

Pressure

Gas

Rate

Gas

Rate

Nominal

CO

Nominal

CO

Nett Flue

Tem p

VPC52 12 1.25 125 27. 0 2.31 8.9 170 8.0 1.24 4.0 118

VPC80 12 1.55 155 24.1 3.55 9.4 151 6.0 1.72 3.4 99

VPC110 10 1.94 194 26.5 4.89 10.4 192 7.0 2.51 4.0 121

VPC130 12 1.94 194 25.0 5.78 9.0 181 7.9 3.19 3.6 114

Electrical Loadings - 1Pha

Electrical

MODEL

Supply

VPC30 230V 1N 0.55 940 4.3 6.5 4.4 7

VPC52 230V 1N 1.1 940 4.2 8.3 4.5 7

VPC80 230V 1N 1.4 940 10.0 19.0 9.4 15

VPC110 230V 1N 1.5 1500 6.7 28.0 9.3 15

VPC130 230V 1N 2.2 1500 9.4 40.0 10.7 15

VPC110 400V 3N 1.5 1500 3.5 17. 5 3.4 5

VPC130 400V 3N 2.2 1500 4.8 25.1 4.5 7

Motor

kW

Nominal

Motor R.P.M.

Max Fan

Amps (A)

Start Amps

(A)

Run Amps

(A)

Fuse Rating

(A)

Heater Specications

High Fire Low Fire

Air Volume

MODEL

Input

(Nett)

Output

kW kW m/s m/h Pa kW dB(A) kg

Input (Nett)

Output

VPC30 32.6 30 18.0 15.7 0.8664 3119 150 0.55 68 178

Maximum

Duct

Resistance

Fan

Motor

Noise

Level

Weight

VPC52 56.5 52 30.4 26.1 1.5884 5718 200 1.10 68 248

VPC80 87.0 80 42.0 36.8 2.3372 8414 225 1.40 76 305

VPC110 119 . 5 110 61.5 53.3 2.9568 10645 150 1.50 72 362

VPC130 141.3 130 78.1 69.0 3.6288 13064 200 2.20 74 410

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 9 of 40

Drive Data - Standard Motor

Motor (a) Motor Pulley (b)

kW Pha RPM Pt no. Size Pt no.

VPC30

VPC52

VPC80

VPC110

VPC130

VPC110

VPC130

Fan Pulley (e)

Size Pt no.

n/a n/a n/a n/a n/a n/a 5.5kW AC3 143000601 7-11A 143000801

0.55 1 940 n/a n/a n/a n/a n/a 1 321 x 321 1402CFAN280/T/15

1.1 1 940 n/a n/a n/a n/a n/a 1 321 x 321 1402CFAN210/T/15

1.4 1 940 n/a n/a n/a n/a n/a 1 381 x 381 1402CFAN580/T/15

1.5 1 1500 140001908 95x1SPA 142000602 1210-24 142003350 2 321 x 321 1402CFAN240/T/2DECK

2.2 1 150 0 140001998 100x1SPA 142000601 1610-28 142161028 2 321 x 321 1402CFAN240/T/2DECK

1.5 3 1500 140001915 95x1SPA 142000602 1210-24 142003350 2 321 x 321 1402CFAN240/T/2DECK

2.2 3 150 0 140002000 100x1SPA 142000601 1610-28 142161028 2 321 x 321 1402CFAN240/T/2DECK

Fan Pulley

TaperLock (f)

Size

Pt no. Size Pt no. Typ e Pt no. Type Pt no.

Belt(s) (g) Contactor/Relay Overload

Motor Pulley TaperLock (c)

Size

Pt no.

Centrifugal Fan (d)

Size Pt no.

type

VPC30

n/a n/a n/a n/a n/a n/a 5.5kW AC3 143000601 7-11A 143000801

n/a n/a n/a n/a n/a n/a 7.5kW A C3 143000600 7-11A 143000801

170 x1SPA 142001689 1610 -25 142003370 A990/38 142109801 7. 5kW AC3 143000600 7-11A 143000801

180x1SPA 142001675 1610 -25 142003370 A105 0/4 0 142110 507 7.5kW AC3 143000600 12-18A 142000800

160x1SPA 142001619 1610 -25 142003370 A990/38 142109801 7. 5kW AC3 143000600 7-11A 143000801

180x1SPA 142001675 1610 -25 142003370 A105 0/4 0 142110 507 7.5kW AC3 143000600 5-8A 142000802

d

e

f

VPC52

VPC80

VPC110

VPC130

VPC110

VPC130

a

b

c

page no. 10 of 40

g

Fan type 2Fan type 1

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

1.3 General Requirements

1.3.1. Related Documents

All VPC heaters comply with the following European Directives:

Energy Related Product Directive: 2009/125/EC* Gas Appliance Directive: 2009/142/EC Electromagnetic Compatibility Directive: 2004/108/EC Low Voltage Directive: 2006/95/EC Machinery Directive: 2006/42/EC

Air heater(s) must be installed in accordance with BS6230 and BS5440 plus any relevant requirements of local and national building codes. * where appropriate

1.3.2 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.

1.3.4 Gas Supply

1.3.4.1 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. The inlet gas pressure under running conditions must not be less than 17.5mb.

1.3.4.2 Meters

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 by all connected equipment.

1.3.4.3. Installation Pipes

Installation pipes should be ﬁtted in accordance with IGE/ UP/2. Pipe work 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.

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.

1.3.3 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. All standard heaters are supplied by 230V - 1ph, 50Hz. 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

1.3.4.4. 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.

1.3.5 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 must terminate in a freely exposed position and be sited to prevent the products of combustion entering any opening in a building in such concentration as to be prejudicial to health or a nuisance.

1.3.6 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

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 11 of 40

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.

page no. 12 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

1.4 Ventilation Air Requirements

Type B ued installations.

Where VPC heaters are installed within the heated space (ie not in a plant room or an enclosure) and having

a building design air change rate of greater than 0.5/h, additional provision for ventilation is not required.

If the building design air change rate is less than 0.5/h, additional provision for natural or mechanical ventilation is required. These being:

Natural Ventilation:

Grilles having a free area of at least 2cm² per kW of rated heat input shall be provided at low level i.e. below the level of the heater ﬂue connection.

Mechanical Ventilation:

Must ensure that the space air change rate is at least 0.5/h, must be of the ‘input’ type and interlocked to ensure the heaters cannot work if the input system is not working.

Type B ued installations.

Where VPC heaters are installed in a plant room or an enclosure (ie not within the heated space)

having combustion air drawn directly from the room and connected to a ﬂue that evacuates the products of combustion directly from the room additional provision for natural or mechanical ventilation is required. These being:

Natural Ventilation:

There must be permanent air vents communicating directly with the outside air, at high level and at low level.

Plant Rooms

Low level (inlet) 4cm²/kw of total rated net heat input High level (outlet) 2cm²/kw of total rated net heat input

Enclosures

Low level (inlet) 10cm²/kw of total rated net heat input High level (outlet) 5cm²/kw of total rated net heat input

Mechanical Ventilation:

The minimum ﬂow rate of ventilation shall be 4.14m³/h per kilowatt of total rated heat input.

Type C ued installations.

Where VPC heaters are Installed within the heated space (ie not in a plant room or an enclosure) having

combustion air ducted to the appliance and combustion products ducted to the outside air, NO additional

provision for the supply of either combustion air or for combustion products dilution or additional provision for the supply of air is necessary.

Type C ued installations.

Where VPC heaters are Installed in a plant room or an enclosure (ie not within the heated space) having

combustion air ducted to the appliance and combustion products ducted to the outside, air vents shall be provided and be permanently open.

To room or internal space

Low level (inlet) 10cm²/kw of total rated net heat input High level (outlet) 10cm²/kw of total rated net heat input

Direct to outside air

Low level (inlet) 5cm²/kw of total rated net heat input High level (outlet) 5cm²/kw of total rated net heat input.

Type B22 Installation (these refer to section 2.2 of these

instructions)

Air vents shall be permanently open. In all cases gures are per heater installed. For multi heater installations the appropriate values for each heater

must be added together

In the

heated

VPC

30 32.6 65.2 130.0 65.2 326.0 163.0 n/a 326.0 326.0 163.0 163.0

52 56.5 113 .0 226.0 113.0 565.0 283.0 n/a 565.0 565.0 283.0 283.0

80 87.0 174.0 348.0 174.0 870.0 435.0 n/a 870.0 870.0 435.0 435.0

110 119.5 239.0 478.0 239.0 1195.0 598.0 n/a 1195.0 1195.0 598.0 598.0

130 141.3 283.0 565.0 283.0 1413.0 707.0 n/a 1413.0 1413.0 707.0 707.0

Input kW

space

Low level

grille. Free

area cm²

In a plant room,

ventilation to

outside

Low level

grille. Free

area cm²

High level

grille. Free

area cm²

In an enclosure,

ventilation to

outside

Low level

grille. Free

area cm²

High level

grille. Free

area cm²

Type C12 or C32 Installation (these refer to section 2.2

of these instructions)

Air vents shall be permanently open. Figures are for heaters in plant rooms or enclosures ONLY In all cases gures are per heater installed. For multi heater installations the appropriate values for each heater

must be added together.

In the

heated

space

Free area grille cm²

Ventilation is to a

room or internal

space

Low level

grille. Free

area cm²

High level

grille. Free

area cm²

Ventilation is to a

outside air

Low level

grille. Free

area cm²

High level

grille. Free

area cm²

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 13 of 40

2.1 Fitting the Unit

Minimum Clearance Distance

C

D*

Model 30 52 80 110 130

A Front mm 1000 1000 1000 1000 1000

B Rear mm 500

C Above mm 1000

D Side (Blank panel)* mm 150

E Side (Louvred)* mm 500

To the front of the heater to nearest wall 1.0m To the rear of the heater to nearest wall 0.5m To the side having louvred lower panels* 0.5m To the side having blank lower panels (see below)* 0.15m Above the heater 1.0m

AE* B

* Side panels are interchangeable to ease with installation against walls etc. Therefore D can = 1.0m if E = 0.15m OR E can = 0.15m if D = 1.0m

page no. 14 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

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.

2.1.4 Minimum Clearances

The minimum clearances for installation and servicing shown opposite must be observed.

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.

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.

2.1.3 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 nal gas

connection to the heater do not place undue

strain on the gas pipe work of the heater.

IMPORTANT:

1. 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.

2.1.2 Fitting the Unit

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 section 1.2) 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 ﬂue system must be so placed or shielded as to ensure that its temperature does not exceed 65 °C.

2.1.4 Air Distribution System 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 section 1.2. 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.

2.1.4 Room Thermostat Siting

The room thermostat 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, should be avoided. The thermostat should be mounted approximately 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 section

2.5 or the accompanying wiring diagram.

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 15 of 40

2.2 Flue/Combustion Air Duct System

The minimum distance between surfaces of the ﬂue pipe and any surfaces made from combustible materials is 300mm. If it is necessary for the ﬂue pipe to pass through a structure made from combustible materials a metal sleeve must be used so that the minimum clearance of 300mm is maintained.

The ﬂue and combustion air ducts supplied with the heater are capable of withstanding their own weight over the allowable ﬂue lengths. Wall bands and bracing brackets, or equivalent, must be used to provide lateral stability and should be used at centres not exceeding 2.5 metres.

All models are supplied as standard with a top ﬂue outlet and the ﬂue outlet and combustion air sockets temporarily ﬁtted.

2.2.1 Conversion to Side Flue Outlet

1. Remove the two blanking plates from the ﬂue / combustion air openings at the side of the unit.

2. Disconnect the ﬂexible pipe from the exhaust spigot.

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.

2.2.3. Installation of Flue System

Note: A terminal guard, as supplied by Powrmatic Ltd, must be ﬁtted to horizontal ﬂue terminals.

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.

2.2.1.2 Internal Combustion Air

1. If ducted combustion air is not required (see Section 1.4) ﬁt the mesh inlet plate (supplied loose) behind the unused combustion air inlet hole.

2.2.2. General Requirements

See Figures 1a to 2b 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 should be used each set being equivalent to

0.5m of ﬂue length. 90° bends may be used but each set will be equivalent to 1.0m of ﬂue length.

The minimum ﬂue length (end of ﬂue terminal to side or top of heater) shall not be less than 1.3m.

2.2.3.1. 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 length 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 oﬀ take 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.

page no. 16 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Fig 1a Exhaust only system - vertical

Type C32 installation

Fig 1b Exhaust only system - horizontal

Type C12 installation

Terminal

Flashing

Single to twin adaptor

6m maximum

Lengths

Combustion air socket

Adjustable lengths

Condensate drain length

Flue socket

2.2.3.2. 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.

Flue socket

Lengths

Adjustable length

Combustion air socket

6m maximum

Single to twin adaptor

Combustion air duct

Terminal

2.2.3.3. Internal Combustion Air System

1. Complete the run of ﬂue sections from the terminal spigot to the ﬂue outlet socket of the heater generally as described in 2.2.3.1. and 2.2.3.2., ensuring that the internal silicon sealing rings are in place.

2. It is recommended that both air inlets are utilized and that both are ﬁtted with the mesh inlet plates supplied.

Fig 2a Individual system - vertical

Type B22 installation

Terminal

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.

Notes for all systems. i) 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.

Lengths

OPTION 1 Combustion air entry

(fitted with inlet grille)

Flashing

12m maximum

Adjustable length

Condensate drain length

Flue socket

OPTION 2 Combustion air entry

(fitted with inlet grille)

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 17 of 40

Fig 2b Individual system - horizontal

Type B22 installation

Flue outlet

Adjustable length

OPTION 2 Combustion air entry

(fitted with inlet grille)

Lengths

12m maximum

Terminal

2.2.4. Condense Length

VPC gas ﬁred heaters (with on/oﬀ burner) A VPC heater ﬁtted with an on/oﬀ burner, an approved ﬂue

terminal & vertical ﬂue run that’s predominantly internal, will typically not require an inline condense drain as ﬂue gas temperatures are higher than the dew point, which is approximately 60°C.

VPC gas ﬁred heater (with high/low & modulating burners) A VPC heater ﬁtted with high/low or modulating burner may require an inline condense ﬂue drain if vertically ﬂued, due to the lower ﬂue gas temperatures experienced when the heater is operating at low ﬁring rates.

Exceptions may occur if the installation requires signiﬁcant length of the ﬂue which may cause chilling, or if heater may be exposed to high winds and heavy rain, which may ingress the ﬂue. We would always recommend ﬁtting the inline condense drain even if the drain point is capped, should the drain be required in the future. Any clariﬁcation can be achieved by consulting with Powrmatic’s Technical Department.

2.3 General Identication of Electrical Items

FAN / LIMIT THERMOSTAT

EXHAUST FAN

PRESSURE SWITCH

GAS VALVE

HIGH LIMIT RESET

MANUAL OVERRIDE SWITCH

BURNER RESET

page no. 18 of 40

CONTACTOR

OVERLOAD

MC200 CAB

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

2.4 Electrical Cable Installation

Electrical Connections

Warning: THIS APPLIANCE MUST BE EARTHED.

Warning: Lockout reset is by a switched Neutral to the controls in the heater.

Warning: Wiring external to the unit must be carried out by an appropriately

qualied person to current IEE regulations for Electrical Installations and any local regulations which apply.

The local 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.

The local electrical supply conditions must be compatible with the electrical data given on the appliance data plate.

Reference must be made to the table below 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.

C= Screened 2 core (MC200 models only)* * (screen must be grounded only at the MC200, See

instructions supplied with controller for wiring sizing, Max. 100m)All units are fully prewired and only require

ﬁnal connections for the incoming mains supply and completion of the control circuit (230V).

The wiring terminals are located behind the front panel which has to be removed.

The mains supply ( single or three phase) connections are via a Hylec terminal block. Control Circuitry connections

are via a 30A numbered terminal strip. They are:

terminal 1 Heat on terminal 2 Fan only terminal 3* 0-10V (modulating) OR 230V High

Fire terminal 4* 0V (modulating negative) terminal 5 Lockout indication terminal 6 Burner reset

* Used where required

Model Phase

30 1 52 1 80 1 110 1 130 1 110 3 130 3

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.

Initial Wiring Instalation Key A = 2 core and earth B = MC200 Hi/Lo = 7 core and earth MC200 Mod = 8 core and earth

Running

Amps (A)

4.4

4.5

9.4

9.3

10.7

3.4

4.5

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 19 of 40

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Installation instructions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

POWRTROL RR

NVx Terminal Numbers

2.5 Wiring Diagrams

VPC 30-80 On/O Gas Cabinet 1Pha

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/2

143070274

143000816

143100663

MC200BL

POWRTROL/RR

Model specific

145030844

143000306

143070274

A. Brahma Control DMN32

B. Honeywell Fan/Limit Thermostat

C. Limit Indicator / Res et Button

D. Air Pressure Switch

E. Main Gas Valve

F. Exhaust / Combustion Fan

G. Main fan

H. Hylec Terminal Block 3 Way

I. NVx Ver 2 Wiring Loom

J. Ignition Electrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface B oard

N. Internal Lockout Reset Button

COMPONENT LIST Powrmatic part #

O. Jox Relay

143000816

P. Engineers Override S witch

Q. MC200 Fuel Saver

R. Powrtrol Remote Reset

S. Ktec Contactor

T. Otec Overload

U. Jox Relay

5

.

1

B

r

5

.

1

B

r

4

1

3

1

T

3

L

3

T

2

L

2

T

1

L

NOTES

1

A

1

2

S

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Installation instructions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

T

3

T

2

T

1

5

9

6

9

T

3 Core

Cable

r

1

.

5

B

l

B

u

1

.

5

e

l

1

.

5

r

G

/

Y

G

E

Br 0.5

Blk 1.0

Blu 1.0

Gry 1.0

F

Br 0.5

Blu 0.5

C

Br 1.0

0

.

5

18

0

.

5

19

0

.

5

20

0

.

5

21

NOTES

K

B

C

°

C

°

N

A

F

ºc

IT

IM

(143000307)

alternative stat

231

NO

COM

654

3

2

5

6

4

0

A

1617181913141

L

7 7 8 8 9

10 11 12 13 14 15 16 17

Note:

Remove Mode Link 'B'

NC

8 9

1

0

1

N

M

p

e

D

y

E

D

3

7

O

M

H

A

R

2

T C

B

E

S

U

F

4

A

1234567

Or 0.5

Blk 0.5

Wh 0.5

Blu 0.5

5 Core

Cable

White Rodgers

Br 1.0

Gry 1.0

r

B

l

B

k

l

B

u

y

r

G

Yel 1.0

Blk 1.0

5

l

B

u

0

.

Br 0.5

9

10

N

L

M

R/S

87

TRP

11

5

J

6

J

1

T

J

2

T

0

5

A

N

J

15

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

8

Note:

Fan Stat - Right Hand Side

Limit Stat - Left Hand Side

16

4 Core

Cable

MAINS SUPPLY

LIVE

EARTH

NEUTRAL

H

NO

NC

U

COM

7 7 8 8

0

.

5

r

B

9

10 11 12 13 14 15 16 17

Or 0.5

0

.

5

ENN

E EE N1

l

B

u

0

.

5

.

5

r

B

N

l

B

u

0

.

r

B

L LL

L

6

6 5

5 4

4 3

3 2

2

W

h

0

.

5

1

I

Or 0.5

Q

L

D

NCNOC

Br 0.5

Or 0.5

Yel 0.5

Wh 0.5

Blu 0.5

Or 0.5

Blu 0.5

Wh 0.5

Blk 0.5

MC200 fuelsaver

L

Or 0.5

E

N

t

u

O

L

t

u

a

O

F

n

a

In

F

n

t

u

O

o

e

a

t L

H

In

o

e

a

t L

H

t

u

O

i

e

a

t H

H

In

i

e

a

t H

H

t

c

o

k

u

L

o

e

s

e

t

R

0

v

-

-1

0

v

+

0

-1

2

IN

M

O

C

1

N

E

S

R

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

Connections

External Controls

Lockout Reset - Neutral Switch

Lockout Indicator 230v Output

Main Fan Only 230V Input

Heat Demand 230V Input

LN2156

NVx Terminal Numbers

65 21

N L

page no. 20 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

VPC 30-80 Hi/Low Gas Cabinet 1Pha

Connections made by Control board Assembler

Connections made by Final Assembler

Note: When the valve

is de-energized the

heater operates in

low fire.

NVx Terminal Numbers

145030844

143000306

143070274

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/3

143070274

142466402

143100663

MC200BL

Powrtrol/RR

Model specific

143000816

A. Brahma Control DMN32

B. Honeywell Fan/Limit Thermostat

C. Limit Indicator / Res et Button

D. Air Pressure Switch

E. Main Gas Valve

F. Exhaust / Combustion Fan

G. Main fan

H. Hylec Terminal Block 3 Way

I. NVx Ver 2 Wiring Loom

J. Ignition Electrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface B oard

N. Internal Lockout Reset Button

O. Hi-Lo Gas Valve Head

P. Engineers Override S witch

Q. MC200 Fuel Saver

R. Powrtrol Remote Res et

S. Ktec Contactor

T. Otec Overload

COMPONENT LIST Powrmatic part #

U. Jox Relay

5

.

1

B

r

5

.

1

B

r

4

1

3

1

T

3

L

3

T

2

L

NOTES

2

T

1

L

1

A

1

2

S

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Installation instructions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

T

3

T

2

T

1

5

9

6

9

T

3 Core

Cable

r

1

.

5

B

l

B

u

1

.

5

e

l

1

.

5

r

G

/

Y

G

E

Br 0.5

Blk 1.0

Blu 1.0

Gry 1.0

F

Br 0.5

Blu 0.5

C

Br 1.0

0

.

5

18

0

.

5

19

0

.

5

20

y

0

.

5

21

B

C

°

C

°

5 Core

Cable

Br 1.0

Gry 1.0

r

B

l

B

k

l

B

u

r

G

Yel 1.0

Blk 1.0

l

B

u

0

.

5

Br 0.5

9

10

N

L

M

231

R/S

87

NO

TRP

11

5

J

6

J

1

T

J

2

T

0

N

A

F

ºc

I

L

IT

M

(143000307)

White Rodgers

alternative stat

7

8

0

.

5

r

B

9

l

B

u

0

.

5

10

11

12

13

14

15

16

17

Or 0.5

Note:

Remove Mode Link 'B'

NC

COM

654

3

2

N

M

p

e

D

y

T

E

D

3

7

5

O

6

4

C

A

M

H

A

R

B

E

S

U

4

A

D

NCNOC

8

Yel 0.5

Wh 0.5

9

1

0

1

2

F

8

Note:

Fan Stat - Right Hand Side

16 15

Br 0.5

Or 0.5

Blu 0.5

Limit Stat - Left Hand Side

NO

NC

U

COM

Br 0.5

Or 0.5

Blu 0.5

L

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

4 Core

Cable

.

5

l

B

u

0

r

B

0

.

5

W

h

0

.

5

r

0

.

5

O

Br 0.5

Q

Blu 0.5

Wh 0.5

Blk 0.5

MC200 fuelsaver

ENN

EE N

L LL

6 5 4 3 2 1

MAINS SUPPLY

Connections

External Controls

LIVE

EARTH

NEUTRAL

H

E

N

L

6 5 4 3 2 1

Main Fan Only 230V Input

Lockout Reset - Neutral Switch

Lockout Indicator 230v Output

Heat Hi Demand 230V Input

Heat Lo Demand 230V Input

I

L

E

N

t

u

O

L

t

u

a

O

F

n

a

In

n

F

t

u

O

o

e

a

t L

H

In

o

e

a

t L

H

t

u

O

i

e

a

t H

H

In

i

e

a

t H

H

t

c

o

k

u

L

o

e

s

e

t

R

0

v

-

0

-1

0

v

+

0

-1

2

IN

M

O

C

1

N

E

S

LN2156

5

Wiring Legend

A

Connections made by Installer

K

J

1617181913141

Wh 0.5

Blu 0.5

N

1234567

Or 0.5

Blk 0.5

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Or 0.5

7

8

O

R

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

POWRTROL RR

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

65 21

NVx Terminal Numbers

N L

page no. 21 of 40

VPC 30-80 Modulating Gas Cabinet 1Pha

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/3

143100663

MC200BL

Powrtrol/RR

Model specific

142400305

142466403

145030844

143000306

143070274

A. Brahma Control DMN32

B. Honeywell Fan/Limit Thermostat

C. Limit Indicator / Reset B utton

D. Air Pressure Switch

E. Main Gas Valve

F. Exhaust / Combustion Fan

G. Main fan

H. Hylec Terminal Block 3 W ay

I. NVx Ver 2 Wiring Loom

J. Ignition Electrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface Boa rd N.O.

P. Engineers Override Sw itch

COMPONENT LIST Powrmatic part #

E

F

Q. MC200 Fuel Saver

C

°

143000816

R. Powrtrol Remote Reset

S. Ktec Contactor

T. Otec Overload

U. Modulating Driver Board

V. Modulating Driver Head

W Jox Relay

B

C

°

5 Core

Cable

5

.

1

B

r

5

.

1

B

r

4

1

3

1

T

3

L

3

T

2

L

2

T

1

L

NOTES

1

A

1

2

S

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Installation instructions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

N

A

F

ºc

IT

IM

L

(143000307)

White Rodgers

alternative stat

8

Note:

16 15

T

3

T

2

T

1

5

9

6

9

T

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

Fan Stat - Right Hand Side

Limit Stat - Left Hand Side

4 Core

Cable

3 Core

Cable

r

1

.

5

B

l

B

u

1

.

5

e

l

1

.

5

r

G

/

Y

MAINS SUPPLY

LIVE

EARTH

NEUTRAL

G

Connections

External Controls

W

NO

Br 0.5

C

Blk 0.75

Blu 0.75

Gry 0.75

Wiring Legend

Connections made by Control board Assembler

Connections made by Final Assembler

Br 0.5

Blu 0.5

Br 0.75

18 19 20 21

Br 1.0

Gry 1.0

r

B

0

.

5

18

l

B

k

0

.

5

19

l

B

u

0

.

5

20

r

G

y

0

.

5

21

Connections made by Installer

K

J

Yel 1.0

Blk 1.0

Br 0.5

7

8

0

.

5

r

B

9

l

B

u

0

.

5

10

11

12

13

14

15

16

17

l

B

u

0

.

5

Br 0.5

9

10

N

L

M

R/S

87

TRP

11

5

J

6

J

1

T

J

2

T

5

A

Or 0.5

231

NO

2

4

0

Note:

Remove Mode Link 'B'

NC

COM

654

3

N

M

p

e

D

y

T

E

D

3

7

O

5

6

C

A

M

H

A

R

B

1617181913141

Blk 0.5

Wh 0.5

Blu 0.5

17

D

NCNOC

8

Yel 0.5

Wh 0.5

9

1

0

1

2

E

S

U

F

4

A

1234567

Or 0.5

C

Br 0.5

Blu 0.5

ON

1 2 3 5 6

U

COM

Br 0.5

Or 0.5

Blu 0.5

L

Or 0.5

2 1

61 62 63 64 65 66

P

NC

.

5

0

.

5

Br 0.5

H

ENN

E

EE N

N

l

B

u

r

B

0

L LL

L

6

5

4

3

2

W

h

0

.

5

1

Lockout Reset - Neutral Switch

Lockout Indicator 230v Output

Modulating Signal 0v

Modulating Signal 0-10v

Main Fan Only 230V Input

Heat Demand 230V Input

I

Or 0.5

Q

L

E

N

t

u

O

Br 0.5

Or 0.5

Blu 0.5

Or 0.5

Yel 0.5

Wh 0.5

Blk 0.5

MC200 fuelsaver

L

t

u

O

a

n

F

In

a

n

F

t

u

O

o

e

a

t L

H

In

o

e

a

t L

H

t

u

O

i

e

a

t H

H

In

i

e

a

t H

H

t

c

u

k

o

L

e

s

e

t

R

0

v

-

0

-1

0

v

+

0

-1

2

IN

M

O

C

1

N

E

S

LN2156

NVx Terminal Numbers

43

R

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

POWRTROL RR

Or 0.5

Yel 0.5

7

8

V

65 21

NVx Terminal Numbers

N L

page no. 22 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

VPC 110-130 On/O Gas Cabinet 3Pha

Connections made by Control board Assembler

Connections made by Final Assembler

Connections made by Installer

POWRTROL RR

NVx Terminal Numbe rs

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/3

143070274

143100663

MC200BL

POWRTROL/RR

Model specific

145030844

143000306

143070274

143000816

5

.

1

B

r

5

.

1

B

r

3

1

4

1

L

3

T

3

L

2

T

2

L

1

T

NOTES

1

A

1

2

T

3

T

2

T

1

6

9

5

9

3 Core

Cable

LN

r

B

1

.

5

l

B

u

1

.

5

r

/

G

e

l

Y

1

.

5

G

M

COMPONENT LIST Powrmatic part #

A. Brahma Control DMN32

B. Honeywell Fan/Limit Therm ostat

C. Limit Indicator / Reset Button

D. Air Pressure Switch

E. Main Gas Va lve

F. Exhaust / Co mbustion Fan

G. Main fan moto r

H. Hylec Terminal Block 3 Way

I. NVx Ver 2 Wir ing Loom

J. Ignition Electrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface Board

N. Internal Lockout Reset Button

P. Engineers Override Switch

Q. MC200 Fuel Saver

R. Powrtrol Remote Reset

S. Ktec Contactor

T. Otec Overload

U. Jox Relay

E

Br 0.5

Blk 1.0

Blu 1.0

Gry 1.0

F

Blu 0.5

C

Br 0.5

Blu 0.5

Br 1.0

r

0

.

5

18

l

k

0

.

5

19

l

u

0

.

5

20

r

y

0

.

5

21

B

C

°

C

°

5 Core

Br 1.0

Gry 1.0

B

G

Yel 1.0

Blk 1.0

l

B

u

0

.

5

Br 0.5

9

10

N

L

M

R/S

87

TRP

11

5

J

6

1

J

T

2

J

T

5

Wiring Legend

A

Cable

White Rodgers

alternative stat

231

NO

COM

654

3

2

6

4

0

1617181913141

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Instal lation instruct ions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

N

A

F

ºc

IT

IM

L

(143000307)

7

8

r

0

.

5

9

u

0

.

5

10

11

12

13

14

15

16

17

Or 0.5

Note:

Remove Mode Link 'B'

NC

NCNOC

8

Yel 0.5

9

0

1

1 1

2

N

M

y

T

p

e

D

3

7

5

E

D

O

C

M

A

H

A

R

B

E

S

U

F

4

A

1234567

Or 0.5

Blk 0.5

Wh 0.5

Blu 0.5

N

K

J

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

S

8

Note:

16 15

T

MAINS SUPPLY

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

Fan Stat - Right Ha nd Side

Limit Stat - Left Ha nd Side

4 Core

Cable

LIVE

EARTH

NEUTRAL

Connections

External Controls

U

NO

NC

COM

u

0

.

5

r

0

.

5

r

0

.

B

l

B

5

0

.

5

.

5

P

Q

Or 0.5

Br 0.5

Or 0.5

Wh 0.5

Blu 0.5

Wh 0.5

Blk 0.5

L

Or 0.5

R

l

r

0

B

h

MC200 fuelsaver

H

ENN

E EE N

N

L LL

L

B

6

6 5

5 4

4 3

3 2

2

W

1

I

L

E

N

t

u

O

L

t

u

a

O

F

n

a

In

F

n

t

u

O e

o

a

t

H

L

In

e

o

a

t

H

L t

u

O

i

e

a

t

H

In

i

e

a

t

H

t

c

o

k

L

u

o

e

s

e

t

R

0

-

1

0

v

-

1

0

v

+

0

-

2

IN

M

O

C

1

N

E

S

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

Lockout Reset - Neu tral Switch

Lockout Indicator 230v Output

Main Fan Only 230V Input

Heat Demand 230V Input

LN2156

NVx Terminal Numbe rs

65 21

N L

page no. 23 of 40

VPC 110-130 Hi/Low Gas Cabinet 3Pha

Connections made by Control board Assembler

Connections made by Final Assembler

Note: When the valve

is de-energized the

heater operates in

low fire.

NVx Terminal Numbe rs

145030844

143000306

143070274

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/3

143070274

142466402

COMPONENT LIST Powrmatic part #

A. Brahma Control DMN32

B. Honeywell Fan/Limit Thermost at

C. Limit Indicator / Reset Button

D. Air Pressure Switch

E. Main Gas Valv e

F. Exhaust / Co mbustion Fan

G. Main fan moto r

H. Hylec Terminal Block 3 Way

I. NVx Ver 2 Wir ing Loom

J. Ignition Electrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface Board

N. Internal Lockout Reset Button

O. Hi-Lo Gas Valve Head

143100663

MC200BL

P. Engineers Override Switch

Q. MC200 Fuel Saver

143000816

Powrtrol/RR

Model specific

NOTES

R. Powrtrol Remote Reset

S. Ktec Contactor

T. Otec Overload

U. Jox Relay

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Install ation instructi ons.

5

.

1

B

r

5

.

1

B

r

3

1

4

1

L

3

T

3

L

2

T

2

L

1

T

1

A

1

2

S

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

T

3

T

2

T

1

6

9

5

9

T

3 Core

Cable

LN

r

B

1

.

5

l

B

u

1

.

5

r

/

G

e

l

Y

1

.

5

M

G

E

F

B

N

A

C

°

C

°

White Rodgers

5 Core

Cable

F

ºc

IT

IM

L

(143000307)

alternative stat

8

Note:

Fan Stat - Right Hand Side

16 15

Limit Stat - Left Hand Side

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

4 Core

Cable

MAINS SUPPLY

Connections

External Controls

LIVE

EARTH

NEUTRAL

U

NO

NC

COM

Br 0.5

Blu 0.5

C

Br 1.0

Blk 1.0

Blu 1.0

Gry 1.0

18 19 20 21

Br 1.0

Br 0.5

Gry 1.0

r

B

0

.

5

18

l

B

k

0

.

5

19

l

B

u

0

.

5

20

r

y

G

0

.

5

21

Yel 1.0

Blk 1.0

7

8

r

B

0

.

5

9

l

B

u

0

.

5

10

11

12

13

14

15

16

17

l

B

u

0

.

5

Br 0.5

9

10

N

L

M

5

J

6

1

J

T

2

J

T

231

Note:

R/S

87

TRP

11

0

Remove Mode Link 'B'

NC

NO

COM

654

3

2

N

M

y

T

p

e

D

3

7

5

6

4

0

E

D

O

C

M

A

H

A

R

B

17

Or 0.5

NCNOC

8 9

0

1

1 1

2

E

S

U

F

4

A

Br 0.5

Or 0.5

Yel 0.5

Wh 0.5

Blu 0.5

L

P

Br 0.5

Blu 0.5

0

.

5

0

.

5

0

.

5

0

.

5

W

h

0

.

5

r

O

0

.

5

Blk 0.5

H

ENN

E EE N

N

l

B

u

r

B

r

L LL

L

B

r

B

6

6 5

5 4

4 3

3 2

2 1

1

Main Fan Only 230V Input

Lockout Reset - Neu tral Switch

Lockout Indicator 230v Output

Heat Hi Demand 230V Input

Heat Lo Demand 230V Input

I

Q

L

E

N

t

u

O

L

t

u

a

F

O

n

a

F

In

n

t

u

O e

a

o

t

H

L

In

e

a

o

t

H

L t

u

O

MC200 fuelsaver

i

e

a

t

H

In

i

e

a

t

H

c

o

t

L

k

u

o

e

s

e

t

R

0

-

1

0

v

-

0

-

1

0

v

+

2

IN

M

O

C

1

N

E

S

Wh 0.5

LN2156

Wiring Legend

Connections made by Installer

page no. 24 of 40

5

A

1617181913141

Wh 0.5

Blu 0.5

N

K

J

1234567

Or 0.5

Blk 0.5

Or 0.5

7

8

O

R

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

POWRTROL RR

65 21

NVx Terminal Numbe rs

N L

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

VPC 110-130 Modulating Gas Cabinet 3Pha

NVx Terminal Number s

Model specific

143100603

147600101

Model specific

142423003

143000526

142403600/3

143070274

143100663

MC200BL

Powrtrol/RR

Model specific

142400303

142466403

145030844

143000306

143070274

COMPONENT LIST Powrmatic part #

A. Brahma Control DMN32

B. Honeywell Fan /Limit Thermostat

C. Limit Indicator / Reset Button

D. Air Pressure Switch

E. Main Gas Valve

F. Exhaust / Com bustion Fan

G. Main fan moto r

H. Hylec Terminal Block 3 Way

I. NVx Ver 2 Wir ing Loom

J. Ignition Ele ctrode

K. Rectification Probe

L. Fuse Holder 3.15A

M. High Limit Interface Board

N. Internal Lockout Reset Button

P. Engineers Override Switch

Q. MC200 Fuel Saver

E

Br 0.5

Blk 1.0

Blu 1.0

Gry 1.0

F

Blu 0.5

C

Br 0.5

Blu 0.5

Br 1.0

0

.

5

18

0

.

5

19

0

.

5

20

0

.

5

21

B

C

°

Br 1.0

Gry 1.0

r

B

l

B

k

l

B

u

r

y

G

5

Wiring Legend

Connections made by Control board Assembler

Connections made by Final Assembler

Connections made by Installer

K

A

J

143000816

NOTES

R. Powrtrol Remote Reset

S. Ktec Contactor

T. Otec Overload

U. GM44 Modulating Driver Board

V. Modulating Driver Head

W. Jox Relay

C

°

(143000307)

5 Core

Cable

White Rodgers

alternative st at

Yel 1.0

Blk 1.0

l

B

u

0

.

5

Br 0.5

9

10

N

L

M

5

J

6

1

J

T

2

J

T

231

R/S

87

NC

NO

TRP

COM

654

11

3

2

N

M

D

3

7

5

6

4

0

E

M

A

H

1617181913141

Or 0.5

Blu 0.5

N

5

.

1

B

r

5

.

1

B

r

3

1

4

1

L

3

T

3

L

2

T

2

L

1

T

1

A

1

2

S

Mains Input: 230v 50Hz 1ph Supply.

For input power refer to Ins tallation instruc tions.

Warning: High voltages present at the ignition

electrode when the unit attemps to light.

N

A

F

ºc

IT

IM

L

8

Note:

16 15

T

3

T

2

T

1

6

9

5

9

T

Br 1.5

Blk 1.5

Blu 1.5

Gr/Yel 1.5

Fan Stat - Right Hand Side

Limit Stat - Left Hand Side

4 Core

Cable

3 Core

Cable

LN

r

B

1

.

5

l

B

u

1

.

5

r

/

G

e

l

Y

1

.

5

MAINS SUPPLY

LIVE

EARTH

NEUTRAL

G

M

Connections

External Controls

W

NO

NC

COM

7

8

r

B

0

.

5

9

l

B

u

0

.

5

10

11

12

13

14

15

16

17

Or 0.5

Note:

Remove Mode Link 'B'

NCNOC

8 9

0

1

1 1

2

y

T

p

e

D

O

C

A

R

B

E

S

U

F

4

A

Br 0.5

Yel 0.5

Wh 0.5

Blu 0.5

L

1234567

Or 0.5

Blk 0.5

Wh 0.5

P

Br 0.5

Or 0.5

Br 0.5

Blu 0.5

.

5

.

5

.

5

.

5

Or 0.5

Yel 0.5

Wh 0.5

Blk 0.5

H

ENN

E EE N

N

l

B

u

0

r

B

0

L LL

L

r

B

0

r

B

0

6

6 5

5 4

4 3

3 2

2

W

h

0

.

5

1

I

Br 0.5

Q

MC200 fuelsaver

R

POWRTROL RR

Lockout Reset - Neutr al Switch

Lockout Indicator 23 0v Output

Modulating Signal 0 v

Modulating Signal 0 -10v

Heat Demand 230V In put

Main Fan Only 230V Inp ut

L

E

N

t

u

O

L

t

u

a

O

F

n

a

In

F

n

t

u

O e

o

a

t

H

L

In

e

o

a

t

H

L t

u

O

i

e

a

t

H

In

i

e

a

t

H

t

c

o

k

u

L

o

e

s

e

t

R

0

-

1

0

v

-

0

-

1

0

v

+

2

IN

M

O

C

1

N

E

S

T

N

E

V

T

N

E

V

e

s

e

t

R

/O

L

P

M

A

L

/O

L

/P

O

K

C

O

L

C

IN

T

A

E

H

T

U

O

T

A

E

H

L

N

LN2156

43

65 21

NVx Terminal Number s

N L

Br 0.5

Blu 0.5

2

1

ON

1 2 3 5 6

U

61 62 63 64 65 66

Or 0.5

Yel 0.5

7

8

V

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 25 of 40

2.6 Commissioning and Testing

2.6.1. Electrical Installation

Checks to ensure electrical safety must be carried out by a qualiﬁed person.

2.6.2. Gas Installation

For new installations, 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.

2.6.3. 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 program

the controls in accordance with their instructions.

IMPORTANT: The internal pipe work 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 uid.

1. Switch on the electrical supply at the isolator.

2. If the limit indicator light comes on press the limit thermostat interlock relay reset switch on the inside panel. The Red indicator light will go out 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.

3. If the burners fail to light the control box will complete a further four ignition attempts. If at the end of ﬁve attempts the burners have still not lit the control box will go to lockout and the amber indicator light, internal and remote lockout lights will be illuminated. To restart the ignition sequence depress the illuminated reset button for about 1-2 seconds.

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) If necessary reset the internal control from lockout by pressing the reset button on the external control for 1-2 seconds.

e) Press the limit interlock reset switch on the electrical panel.

f) Ensure that the Summer/Winter switch is in the Winter position.

g) On ducted systems check that all warm air delivery outlets are open.

h) Turn ON the gas supply.

2.6.4. Lighting the Air Heater

2.6.5 Adjustments

2.6.5.1. Burner Gas Pressures

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.

2.6.5.1.1. High/Low Regulation

1. Set external controls to ensure the main burner is oﬀ. Open the side access panel. Connect a pressure gauge to the burner pressure test point on the multifunctional control.

2. Set external controls 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 ensuring that no other appliances supplied through the meter are in operation.

NOTES: On initial lighting of the heater(s), it may take some time to purge the internal pipe work of air.

page no. 26 of 40

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

4. If it is necessary to adjust either the high ﬁre or low ﬁre pressures proceed as follows after levering oﬀ the plastic cover from the Hi/Lo regulator.

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Model 30 52 80 110 130

Natural Gas G20

High Fire CO %

Low Fire CO %

8.6 8.2 8.0 9.0 7.2

3.7 3.1 2.7 3.2 3.4

Propane G31

High Fire CO %

Low Fire CO %

11. 0 8.9 9.4 10.4 9.0

4.6 4.0 3.4 4.0 3.6

Note: High ﬁre setting must be adjusted ﬁrst after which the low ﬁre setting can be set. Any adjustment of the high ﬁre setting alters the minimum setting.

Maximum Setting

With the controls set to high ﬁre use an adjustable or 8mm spanner to turn the adjustment screw for high ﬁre pressure, clockwise to increase and counter-clockwise to decrease, until the required pressure is obtained. Turn the burner On and OFF several times to check the pressure setting and then turn oﬀ.

Minimum Setting

Disconnect electrical connection of high/low regulator and turn burners back on and wait until the burner pressure has stabilized. Use a screwdriver to turn the slotted adjustment screw for low ﬁre pressure, clockwise to increase and counter-clockwise to decrease, until the required pressure is obtained. Reconnect high/low regulator and check high ﬁre pressure. Repeat both steps if necessary and then replace cover cap.

5. Turn oﬀ the main burner, disconnect the pressure gauge and replace the sealing screw. Turn on the main burner and test for gas soundness around pressure test joint using a leak detection ﬂuid. Replace access panel.

Hexagonal adjustment screw for maximum pressure setting

Cover Lever point

Internal slotted adjustment screw for minimum pressure setting

2.6.5.1.2. Modulating Regulation

1. Set external controls to ensure that the main burner is oﬀ. Open the front 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 ensuring 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 either the high ﬁre or low ﬁre pressures proceed as follows after removing the plastic cover from the Modulating regulator.

Note: Minimum ﬁre setting must be adjusted ﬁrst after which the high ﬁre setting can be set. Any adjustment of the minimum ﬁre setting alters the maximum setting.

Shaft

Cap

Adjustment nut (7mm) for maximum pressure setting

Adjustment nut (9mm) for minimum pressure setting

‘O’ ring

6.3mm AMP terminals

Hi/Low Regulator

Modulating Regulator

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 27 of 40

Minimum Setting

Disconnect electrical connection of modulating regulator and turn burners back on and wait until the burner pressure has stabilized. Turn 9mm adjustment nut for low ﬁre pressure clockwise to increase and counter-clockwise to decrease until the required pressure is obtained. Reconnect modulating regulator and check high ﬁre pressure, readjust if necessary.

The MIB interfaces between a 0-10VDC control signal and the modulating regulator. The following are applicable to this application.

1. The setting of the slide switches 1 & 2 should both be to OFF.

Maximum Setting

Disconnect electrical connection of modulating regulator and turn burners back on and wait until the burner pressure has stabilized. Push shaft gently downwards to the maximum adjustment screw and hold there. Turn 7mm adjustment nut for high ﬁre pressure, clockwise to increase and counter-clockwise to decrease, until the required pressure is obtained. Release shaft. Repeat both settings if necessary and then replace cover cap.

5. Turn oﬀ the main burner, disconnect the pressure gauge and replace the sealing screw. Turn on the main burner and test for gas soundness around pressure test joint using a leak detection ﬂuid.

2.6.5.1.3. Modulating Interface Board

2. Potentiometer P1 (Default setting 100%) The control current of the V7335A is controlled by P1, varying between 50% and 100% of the input signal. E.g.

-When P1 is set at 100% (fully clockwise) maximum power (165mA @ 22VDC) is provided to the modulation coil with a 10VDC input control signal.

-When P1 is set at 50% (fully anticlockwise) maximum power (165mA @ 22VDC) is provided to the modulation coil with a 5VDC input control signal.

3. Potentiometer P2 Controls the minimum drop-out voltage between 0% and

40% E.g.

- When P2 is set at 0% the drop-out voltage with an input control signal of 0-10V-DC is 0.3V-DC.

- When P2 is set at 40% the drop-out voltage with an input control signal of 0-10V-DC is 4.0V-DC.

4. Potentiometer P3 (Default setting 100%) Controls the maximum hold-in voltage. Its proportional

value is added to the P2 setting E.g.

- When P2 is set at 0% and P3 is set at 5%, the hold-in voltage of the burner relay is adjustable between 5% and 100% of the input control signal. If the input control signal is set at 0-10V-DC the hold-in voltage of the relay is 0.5VDC.

- When P2 is set at 40% and P3 is set at 5%, the hold-in voltage of the burner relay is adjustable between 45% and 100% of the input control signal. If the input control signal is set at 0-10V-DC the hold-in voltage of the relay is 4.5VDC.

The following table shows the relationship between P2 and P3 settings.

Modulating Interface Board

page no. 28 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

P3%

Drop Out

P2%

0 10 20 30 40

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.

4. If required, after checking or setting the burner pressures, the CO 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 CO values are given for guidance in the table at the bottom of the previous page.

5. Turn oﬀ the main burner 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.

Volts

0.3 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7. 0 8.0 9.0 10.0

1.0 1.5 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

2.0 2.5 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

3.0 3.5 4.0 5.0 6.0 7.0 8.0 9.0 10.0

4.0 4.5 5.0 6.0 7.0 8.0 9.0 10.0

5 10 20 30 40 50 60 70 80 90 100

2.6.5.2. Flame Current

1. To measure the ﬂame current connect a multimeter capable of measuring micro amps as shown in the following diagram.

Hold-in Voltage

2.6.5.3. 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 may attempt ﬁve 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

2.6.6. Fan/Limit Thermostat

Ensure that the fan and limit settings are as follows:Thermostat settings:-

Fan O: 86°F/30°C Fan On: 122°F/50°C

Limit: VPC 30, 52 212° F/100°C

VPC 80, 110,130 230°F/110°C

2. Minimum current reading is 0.5µA and normal value should be 1.5µA or higher.

Flame Current Measurement

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

2.6.7. Handing over the Air Heater

Hand these 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.

page no. 29 of 40

2.7 Servicing

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed, adjusted and, if necessary, converted by qualied 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.

* An approved class of person listed on the gas safe register.

WARNING: Always switch o and disconnect electricity supply and close the gas service valve before carrying out any servicing work or replacement of failed components.

2.7.1. General

Full maintenance should be undertaken not less than once per year by a qualiﬁed person.

No 'specialised 'tools will be required to carry out this service.

removing the four screws.

5. If required remove the manifold by removing the four screws securing it to the burner assembly.

6. Remove the two screws that secure the top of the burner assembly to the bulkhead and lift out burner assembly.

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

8. Reassemble the injectors, manifold and burners in reverse order to that above.

2.7.3. Ignition and Rectication Electrodes

Note: The ignition electrode is located at the bottom of the burner assembly, the rectiﬁcation electrode is located at the top of the burner assembly.

A fault ﬁnding guide is given in section 3.1 to aid servicing.

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 2.6.

To commence servicing, ﬁrstly open the front access door by rotating the quarter turn screw(s).

2.7.2. Main Burner Assembly Removal

1. Ensure that the gas service valve is turned OFF and then unscrew the union nut situated immediately downstream of it.

2. Disconnect the spark and rectiﬁcation leads from the control box and remove the electrical plug connections from the top of the gas control valve assembly.

3. Remove the burner heat shield, 3 screws.

4. Release the inlet connection ﬂange from the gas valve by

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 and that the rectiﬁcation probe is 10 12mm forward of the burner.

2.5mm

Ignition Electrode Spark Gap

2.7.4. Heat Exchanger

Whilst the main burner assembly is removed from the unit, check that the primary sections that the burners ﬁre into are clean.

2.7.5 Main Fan Assembly

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.

page no. 30 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

2.7.6. Replacement of Faulty Components

2.7.6.4. Fan/Limit Thermostat

Only parts supplied via or authorised by Powrmatic should be used. A short list of parts and part numbers are detailed in section 3.2 of this manual. If in doubt, please contact Powrmatic.

2.7.6.1 Multifunctional Control

1. If there is movement available on the incoming gas pipe work e.g. a ﬂexible connection has been used go to step 2 otherwise remove the burner assembly as previously described in Section 2.7.2.

2. Remove the electrical plug connections from the top of the multifunctional control.

3. Release the ﬂanged connections at the inlet and outlet of the multifunctional control and remove the multifunctional control.

4. 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.

2.7.6.2. Burners

1. Remove the burner assembly as described in Section

2.7.2.

Thermostat settings:-

Fan O: 86°F/30°C Fan On: 122°F/50°C Limit: VPC 30, 52 212° F/100°C

VPC 80, 110,130 230°F/110°C

1. Undo cover retaining screw

2. Squeeze the sides of the cover and remove cover by pulling forward.

3. Release wiring from clamp terminals by pushing a small screwdriver into the clamp release holes adjacent to the clamps.

4. Remove the 2 screws securing the thermostat to the heater panel and withdraw thermostat.

5. Reassemble new unit in reverse order referring to the heater wiring diagram to ensure correct wiring as detailed in section 2.5.

Important: A replacement fan/limit thermostat may have a brass link between the terminals.

This MUST be removed, before the replacement thermostat is installed.

Mechanical Limiter

Release Point

Fan ON

Set Point

Adjuster

Set Point Dial

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 2.6.

2.7.6.3. Electrode Assemblies

1. Disconnect the electrode leads from the control box 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 section 2.7.3) and the rectiﬁcation electrode is 10 - 12mm forward of the burner.

Mechanical

Limiter

Fan OFF

Set Point

Adjuster

Fan Circuit

OUT

Fan ON

Override

Fan Circuit

IN

T I O N

A U

C

DO N O T RO TAT E - HOLD

DIAL WHEN SETTING POINTER

Brass Link

Location

T

I

5

M

I

L

F

N

A

O

N

F

O

F

5

0

1

0

5

2

F

0

O

0

2

0

Limit Set

Point

Adjuster

Limit Circuit

OUT

Limit Circuit

IN

Thermostat Fan / Limit – Honeywell L4064B NOTE: Temperature points on the dial are in Fahrenheit

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 31 of 40

2.7.6.5. Exhaust Fan

2.7.6.8. Centrifugal Fan/Motor

1. Remove the ﬂexi ﬂue from the ﬂue outlet socket.

2. Disconnect the fan electrical connections from the main terminal strip

3. Remove the screws securing the fan mounting box to the exhaust header plate.

4. Remove fan assembly.

5. If needed, transfer the fan mounting box to the replacement fan.

6. Fit replacement exhaust fan, using new gaskets and silicon sealant as necessary, and reassemble in reverse order.

7. Replace the ﬂexi ﬂue.

2.7.6.6. Air Pressure Switch

1. Disconnect the electrical connections to the centrifugal fan section.

2. Remove the lower and top side panels of the unit for access to the fan and motor.

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 replacements as appropriate and reassemble in reverse order.

Note: If a 3ph motor is being replaced ensure that the direction of rotation is correct. If it is not interchange any two of the three phases connected to the motor.

1. Remove the two screws securing the cover and remove cover.

2. Disconnect electrical connections.

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

4. Note the setting of the old pressure switch.

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

6. Fit replacement in reverse order reﬁtting the sensing tube to the negative (- or L) tapping on the pressure switch. Adjust setting to that of the old pressure switch.

2.7.6.7. Control Box

1. Unplug all the electrical connections.

2. Remove the two screws that secure the control box in place.

3. Fit replacement in reverse order.

page no. 32 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

3.1 Fault Finding

Yes

START

Gas & Electrical supplies present at heater? No Turn supplies on, Check fuses/connections

Unit at lockout (lockout lamp on low level controls

and on internal control panel alight)?

No

Limit thermostat tripped (red lamp on front panel on)?

No

Check for 230V at terminal 1 of terminal strip

Yes

Check for 230V at terminal 19

Yes

Check Fuse ‘L’

OK

230V Between 1 & 2 on Brahma control?

Yes

Check fuse on Brahma control

OK

Exhaust fan runs?

Yes

Failed

No

Yes

Absent

Failed

Absent

Replace (4A), ascertain cause and rectify

Check for 230V between terminals 12 & 11 of the terminal strip

Press lockout reset button on low level controls or on internal control panel

Press reset switch on front panel when unit is cool If it will not reset when cold - check/change thermostat, check limit interlock relay operation

External control circuit not calling for heat

Main fan running - wait for unit temperature to reduce - Press reset switch on front panel. If it will not reset when cold - change thermostat, check limit interlock relay operation

Replace (3.15A), ascertain cause of failure and rectify

Check for faulty connection. Replace as necessary.

Absent

Present

Continuity between APS C and NO connections - check for reason, adjust APS setting or change APS. Faulty Brahma control or connections.

Check connections, Faulty exhaust fan and/or capacitor

230V at APS Terminal C ?

Yes

230V at APS Terminal N.O ?

Yes

Ignition sparks?

Yes

Gas valve opens?

Yes

Burners light?

Yes

Burners remain alight?

Yes

Finish

Absent

No

NoMain fan runs?

Check APS sensing tube. Check negative pressure developed by exhaust fan. Adjust APS set point. Change APS

Check/replace ignition probe/lead. Faulty Brahma control box

Check for 230V between terminals 13 & 14 of the terminal strip

Exhaust fan continues to run APS has lost C. to N.O. continuity, slightly reduce APS set point.

4 more ignition attempts then lock out.

Check for 230V between terminals 7 & 15 of the terminal strip

Depending on fan /motor type - Check for 230V at the main fan motor

Replace motor, capacitor or fan/motor assembly

Check connections, Faulty Brahma Control

Check ignition electrode position. Is gas pipe work purged of air? Check gas pressures. Replace gas valve

Present

Yes

No

Absent

Faulty Gas Valve

Check connections, Faulty Brahma Control

Absent

Check connections, overloads etc as applicable

Check connections. Fan/limit thermostat faulty - check/replace

Note: APS = Air Pressure Switch

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 33 of 40

3.2 List of Parts

Item Description Usage Part No.

Gas Valve VR4605AB 30-80 145035204/KIT

Gas Valve V425AB 110, 130 141378715/KIT

Ignition Electrode

30-80 110, 130

Rectiﬁcation (Flame Sensor) Probe All 142423003

30-80

Burner

110, 130

Fan & Limit Thermostat L4064 All 143000306

Control Box (Sequence Controller) All 145030844

142423002 142400004

142400240 142400241

Hi/Lo Governor Head 30-130 -/HL 142466402

Modulation Governor Head 30-130 -/MOD 142466403

Modulation Driver (GM44) 30-130 -/MOD 142400303

Limit Interlock P.C.B. MkIII All 142403600/3

page no. 34 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

'JOX' 230V Relay All 143000816

Pressure Switch Dungs LGW All 146522174

Exhaust Fan 30/52 VP3052EXH

Exhaust Fan 80 - 130 VP80130EXH

Main Centrifugal Blower

Contactor

Overload

Motor

Motor Pulley

30 52 80 110/130

30/52 80/110/130

30/52 80/110 1301P 1303P

110 1p 110 3P 130 1P 130 3P

110 130

1402CFAN280/ T/15 1402CFAN210/T/15 1402CFAN580/T/15 1402CFAN240/T/2DECK

143000601 143000600

143000801 143000801 142000800 142000802

140001908 140001915 140001998 140002000

142000602 142000601

Motor Taperlock

110 130

110 1P

Fan Pulley

110 3P 130

Fan Taperlock ALL 142003370

110

Belts

130

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

142003350 142161028

142001689 142001619 142001675

142109801 142110507

page no. 35 of 40

3.3 Gas Conversion

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are

installed, adjusted and, if necessary,

converted by qualied 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.

* An approved class of person listed on the gas safe register.

3.3.1. General

Heater conversion between gases will require a change of burner injectors, alteration of burner pressure and re-commissioning of the heater. (Refer to section 2.6 for commissioning details.)

Ensure that the gas inlet pressure to the heater

is correct for the new gas, and that the gas

supply has been purged of the old gas. (Refer

to tables opposite for new gas inlet pressures.)

3.3.2. Burner Conversion

3.3.3.1. Sigma 843 Adjustment

Cap

Adjustment nut (10mm) for maximum pressure setting

Adjustment screw for minimum pressure setting

3.3.3.2. Honeywell High/Low Adjustment

Hexagonal adjustment screw for maximum pressure setting

Cover Lever point

Internal slotted adjustment screw for minimum pressure setting

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

2. Remove the burner heat shield, 3 screws.

3. Release the outlet connection ﬂange from the gas valve by removing the four screws.

4. Remove the manifold by removing the four screws securing it to the burner assembly.

5. Remove the main burner injectors and washers.

6. Replace with the new injectors/washers for the new gas ensuring a gas tight seal.

7. Reﬁt all other components in reverse order.

3.3.3. Gas Valves

All gas valves used on the VPC range have pressure regulators that may be set to operate on natural gas or propane (LPG).

Conversion is carried out by adjusting the high and low burner pressures to the value in the tables opposite.

(Refer to full regulator adjustment in section 2.6.5.1)

3.3.3.3. Honeywell Modulating Adjustment

Shaft

Cap

Adjustment nut (7mm) for maximum pressure setting

Adjustment nut (9mm) for minimum pressure setting

‘O’ ring

6.3mm AMP terminals

Note*: Ensure the original data badge is removed and replaced with new data badge and "change of gas" stickers.

page no. 36 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Natural Gas to Propane (LPG) Conversion Data

Nominal Inlet Pressure = 37mbar, Minimum Inlet Pressure = 37mbar

Injectors

MODEL

VPC30

VPC52

VPC80

VPC110

VPC130

Conversion Kit

part number

VPC30LPG

VPC52LPG

VPC80LPG

VPC110LPG

VPC130LPG

No. Size (mm)

6 1.36 136

12 1.25 125

12 1.55 155

10 1.94 194

12 1.94 194

Marked

Injector part

Propane (LPG) to Natural Gas Conversion Data

Nominal Inlet Pressure = 20mbar, Minimum Inlet Pressure = 17.5mbar

Injectors

MODEL

VPC30

Conversion Kit

part number

VPC30NG

No. Size (mm)

6 1.94 194 142401664 13.8 4.6

Marked

Injector part

number

142401661

142401675

142401664

number

High Fire Low Fire

Burner

Pressure

mbar mbar

21.7 7. 0

27.0 8.0

24.1 6.0

26.5 7.0

25.0 7. 9

High Fire Low Fire

Burner

Pressure

mbar mbar

Burner

Pressure

Burner

Pressure

VPC52

VPC80

VPC110

VPC130

VPC52NG

VPC80NG

VPC110NG

VPC130NG

12 1.94 194 142401664 10.4 3.0

12 2.54 254 142401665 8.1 2.1

10 3.00 300 142401670 10.2 3.2

12 3.00 300 142401670 10.0 3.6

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 37 of 40

Appendices

Information required for ecodesign (ErP) Directive 2009/125

Model 30 52 80 110 130

Rated Heat Capacity

Low Heat Input

Minimum Heat Capacity

Useful Efficiency

Nett CV kW 18.9 30.0 41.6 62.2 81.2

High Fire % 92% 92% 92% 93% 93%

Low Fire % 88% 88% 89% 90% 89%

High Fire kW 0.05 0.05 0.05 0.05 0.05

kW 30.4 52.7 80.0 11.4 139.7

kW 16.6 26.4 36.9 55.9 72.4

Electrical Power Consumption*

NOx Seasonal (Gross)

Envelope Loss Factor

Emission Effiency

Seasonal Space Heating Energy Efficiency

Low Fire kW 0.05 0.05 0.05 0.05 0.05

Standby kW <0.01 <0.01 <0.01 <0.01 <0.01

Ignition kW

0.00 0.00 0.00 0.00 0.00

mg/kWh

% n/a n/a n/a n/a n/a

% hs, flow 94.8% 94.8% 95.0% 94.2% 93.9%

% hs,h 72.02% 72.08% 73.56% 72.58% 72.89%

132.4 115.5 128.8 139.9 139.7

page no. 38 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Notes

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

page no. 39 of 40

More information is available from our web site on:-

http://www.powrmatic.co.uk/products/heating/browse/view/product/vpc-gas-cabinet-heaters-2/

HEATING DIVISION

Hort Bridge

Ilminster, Somerset TA19 9PS

Tel: 01460 53535

Fax: 01460 52341

Every effort is made to ensure accuracy at time of going to press. However as part of continued product improvement,

we reserve the right to alter specication without prior notice.

page no. 40 of 40

VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.

Powrmatic VPC Series, VPC52, VPC30, VPC110, VPC80 User, Installation & Servicing Manual

Specifications and Main Features

Frequently Asked Questions

User Manual