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

[phone]

[e-mail]

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: [phone] Fax: [phone]
Web: www.powrmatic.co.uk e-mail: [e-mail]

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

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

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

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

Nett Flue

Tem p

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.