Powrmatic VPC 30, VPC 80, VPC 110, VPC 52, VPC 130 User, Installation And Servicing Instructions
Issue 5.1 Sept 2014
Users, Installation and Servicing Instructions
(Brahma Control, L4064)
WARNING: THIS APPLIANCE MUST BE EARTHED
IMPORTANT: Reset from Lockout is by a switched Neutral
GB & IE H E A T I N G / / V E N T I L A T I O N / / A I R C O N D I T I O N I N G
VPC Gas Cabinet Heater Range
Industrial & Commercial Heating Systems.
powrmatic
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 documentat
ion.
3. As much detail as possible on the fault.
Your supplier, of 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 regognised instraller, and in
accordance with the manufactures 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 manufactures instructions.
5. The correct specification fuel has been used.
6. No unauthorised repairs of modifications have been made.
7. Powrmatic ‘General Conditi
ons of Sales’ have been observed.
8. Except for the obligation of Powrmatic Ltd to perform warranty repairs during the
guarantee period Powrmatic will not be liable in repect 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
1. Gaskets and fan belts are not included in the guarantee.
----------------------------------------------------
Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS
Tel:01460 53535 Fax: 01460 52341
Web: www.powrmatic.co.uk e-mail service@powrmatic.co.uk
Important: This certificate must
be kept with the appliance
Failure to provide a copy of the commissioning sheet invalidates the heater waranty
Page 2 VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014
Installer
Date :_____________ Signed ____________________________________________Installer
Commissioned
Date :_____________ Signed _______________________________Commissioning Engineer
Dear Customer - thank you for choosing Powrmac.
We appreciate you buying one of our high quality products and know that you have made the best
choice. By choosing Powrmac, you are invesng 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 quesons or concerns regarding this product, please contact our Technical Support Team by
calling 01460 53535.
Users, Installaon and Servicing Instrucons
CONTENTS
Title Secon Contents Page
User Instrucons 4
Pre Installaon
1.1 Introducon 5
1.2 General Requirements 6
1.3 Size Data 8
Installaon
2.1 Fing the unit 9
2.2 Fing the Flue 10
2.3 General Idenficaon of Electrical Items 13
2.4 Electrical Cable Instrallaon 14
2.5 Commissioning and Tesng 14
Data
3.1 Technical Data 17
3.2 Short List of Parts 19
Addional Documents
4.1 Servicing 21
4.2 Funconal Flow Diagram 23
VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014 Page 3
Users Instructions
Page 4 VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014
A) 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.
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 front panel of the heater. (Note: This
step is not performed again unless there
is an interruption in the electrical supply
to the heater).
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.
B) Lighting the Air Heater
NOTE:On initial lighting of the heater(s), it may
take some time to purge the internal pipework of
air. If it is not possible to light the heater after
several attempts contact the local service company.
1. Set the controls to call for heat and the ignition
start up sequence will commence. The internal
exhaust fan will run. When sufficient combustion
airflow is proved by the air pressure switch the
ignition spark will be generated and the main gas
valves energized. The burners will then light.
2. If the burner fails to light the control box will
attempt four further ignition attempts before going
to lockout. The lockout light on the MC200 or
Powrtrol will be illuminated (Note: If an integral
MC200 or Powrtrol are not used a remote lockout
indicator/reset will be fitted). To restart the ignition
sequence, depress the reset button on the control
for 1-2 seconds. If the unit will not light after two
or three attempts then shut down the unit and call
in a service engineer.
C) To Shut Down the Air Heater
1) For Short Periods:
Turn the room thermostat to the OFF or lowest setting.
2) For Long Periods:
Complete step 1) above. Wait for 5 minutes and then turn
OFF the electrical supply at the isolator.
D) Description of Operation
Important: All heaters must be controlled by the
fitted external controls and not by use of the main
switch in the electrical supply to the heater.
1) Standard Units
The ignition sequence will commence each time that the
external controls e.g. Time clock, room thermostat etc.
call for heat. Approximately 15 – 30 seconds after the
main burners light the heater fan will be automatically
started. When the external controls are satisfied the main
burners will be turned off and approximately 2 - 3 minutes
later the heater fan will be automatically stopped.
2) High / Lo & Modulating Units
When the main burners are alight the heat output will be
controlled either to high fire or low fire or, in the case of
modulating units, to any point between high and low fire;
depending on the requirements of the space being heated
and the control system.
3) Summer / Winter Modes
The integral MC200 or Powrtrol controls, and certain
types of external controls, will provide for two modes of
operation i.e.
Summer: The heater fan alone will run at the
dictate of the external controls to provide
air movement.
Winter: The heater will operate normally.
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 (Refer to Figure 1) 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. See Section 2.5
ii) Limit Thermostat
This operates if high temperatures within the heater are
detected, the burners are turned off and a red indicator
light on the front of 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.
Note: The limit thermostat interlock relay will
require resetting after loss of the electrical supply
to the heater regardless of whether the limit
thermostat has operated.
E) Maintenance
Regular servicing is essential to maintain efficient, reliable
and safe operation of the heater. Users are strongly
recommended to have the heater serviced by a qualified
person at least annually and preferably at the end of the
heating season.
F) 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 as supply - DO NOT USE A NAKED FLAME and contact the local gas undertaking immediately.
All Powrmatic heaters use gas and electricity to
power them, they may also contain moving parts
such as pulley belts. It would be hazardous to
tamper with or attempt to service unless you are
a competent person in the field of Gas and Electrical work. If you have any safety questions reference the servicing and installation of any of
our heaters please do not hesitate to contact our
head office for expert advice.
Your safety is paramount to us.
Gas Safety (Installation & Use) (Amendment)
Regulations
It is law that all gas appliances are installed,
adjusted and, if necessary, converted by qualified
persons* in accordance with the current issue of
the above regulations. Failure to install appliances correctly can lead to prosecution. It is in your
own interests and that of safety to ensure
that the law is complied with.
* An approved class of person listed on the gas
register.
VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014 Page 5
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 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 one set of atmospheric
inshot burners having a fully automatic control for ignition,
PUSH MAN
PULL AUTO
Honeywell
Fig 1. Limit Thermostat
White
Fan
button
Page 6 VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014
1.2 General Requirements
1.2.1 Related Documents
The installation of the air heater(s) must be in accordance
with the rules in force and the relevant requirements of the
Gas Safety Regulations, Building Regulations and the
I.E.E. Regulations for Electrical Installations.
It should also be in accordance with any relevant requirements of the local gas region, local authority and fire
authority and the relevant recommendations of the following documents.
Institution of Gas Engineers & Managers
IGE/UP/1 (Ed.2) Strength and tightness testing and purging of industrial and commercial gas installations.
IGE/UP/1A Soundness testing and direct purging of small
low pressure industrial and commercial gas installations.
IGE/UP/2 Gas installation pipe work, boosters and compressors on industrial and commercial premises.
IGE/UP/10 Installation gas appliances in industrial and
commercial premises.
British Standards Code of Practice
BS 5588 Fire precautions in the design and construction
of buildings.
Part 2 : 1985 Code of Practice for Shops
Part 3 : 1983 Code of Practice for Office Buildings
BS 6230: 1991 Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial Space
Heating.
Those appliances having a gross input rating not exceeding 60kW viz. VPC30, and installed so as to take their
combustion air from within the building must be installed
in accordance with the relevant recommendations of the
following document.
BS 5440 Flues and Air Supply for gas appliances of rated
input not exceeding 60kW (1st and 2nd family gases),
Part 2 – Air Supply
1.2.2 Location
The location chosen for the air heater must permit:
- the provision of a satisfactory flue system and an
adequate air supply.
- adequate space for servicing and air circulation around
the air heater.
The heater(s) must not be installed in conditions for which
it is not specifically designed e.g. where the atmosphere is
corrosive or salty. Standard units are not suitable for
outdoor location.
Where the location of the air heater is such that it might
suffer external mechanical damage e.g. from overhead
cranes, fork lift trucks, it must be suitably protected.
VPC units are designed to operate within an ambient
temperature range of -10 to 25°C.
1.2.3 Gas Supply
1.2.3.1 Service Pipes
The local gas undertaking should be consulted at the
installation planning stage in order to establish the availability of an adequate supply of gas. An existing service
pipe must not be used without prior consultation with the
local gas undertaking.
1.2.3.2 Meters
A gas meter is connected to the service pipe by the local
gas undertaking or a local gas undertaking contractor. An
existing meter should be checked, preferably by the gas
undertaking, to ensure that the meter is adequate to deal
with the total rate of gas supply required.
1.2.3.3. Installation Pipes
Installation pipes should be fitted in accordance with
IGE/UP/2. Pipework from the meter to the air heater must
be of adequate size. Do not use pipes of a smaller size
than the inlet gas connection of the heater. The complete
installation must be tested for soundness as described in
the above Code.
1.2.3.4. Boosted Supplies
Where it is necessary to employ a gas pressure booster
the controls must include a low pressure cut off switch at
the booster inlet. The local gas undertaking must be
consulted before a gas pressure booster is fitted.
flame sensing, gas supply control and safety functions
and an internal exhaust fan, as well as the main air fan(s)
and limit thermostat.
IMPORTANT
Service and Maintenance Engineers shall ensure
that replacement items are fitted, 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
It is law that all gas appliances are installed,
adjusted and, if necessary, converted by qualified
persons* in accordance with the current issue of
the above regulations. Failure to install appliances correctly can lead to prosecution. It is in your
own interests and that of safety to ensure that the
law is complied with.
* An approved class of person listed on the gas
register.
1.2.4 Flue System
VPC units must be used with a closed flue system and
have an internal exhaust fan, mounted downstream of the
heat exchanger, to both assist the evacuation of the products of combustion and to draw in air for combustion.
The flue should terminate in a freely exposed position and
must be so situated as to prevent the products of combustion entering any opening in a building in such concentration as to be prejudicial to health or a nuisance.
1.2.5 Combustion Air Supply
Where VPC units are to be installed within the space
being heated and take the air for combustion from that
space then for buildings having a design air change rate
of less than 0.5/h, and the heated space has a volume
less than 4.7 m³/kW of total rated heat input grilles shall
be provided at low level as follows:-
(1) for heaters of heat input less than 60 kW, the
total minimum free area shall not be less than
4.5 cm² per kilowatt of rated heat input.
(2) for heaters of heat input 60 kW or more, the total
minimum free area shall not be less than
270cm² plus 2.25 cm² per kilowatt in excess of
60 kW rated heat input.
Where the air heater(s) are to be installed in a plant room
the plant room must have permanent air vents communicating directly with the outside air, at high level and at low
level. Where only high level air vents are available, ducting down to floor level for the lower vents should be used.
All air vents should have negligible resistance and must
not be sited in any position where they are likely to be
easily blocked or flooded or in any position adjacent to an
extraction system which is carrying flammable vapour.
Grilles or louvres should be so designed that high velocity
air streams do not occur within the plant room.
The basic minimum effective area requirements of the air
vents are as follows:
(a) Low Level (inlet)
1. for heaters of total rated heat input less than
60kW: 9cm² per kilowatt of rated heat input.
2. for heaters of total rated heat input 60kW or
more:540 cm² plus 4.5 cm² per kilowatt in
excess of 60kW total rated input.
(b) High Level (outlet)
(1) for heaters of total rated heat input less than
60kW: 4.5cm² per kilowatt of rated heat input.
(2) for heaters of total rated heat input 60kW or
more: 270 cm² plus 2.25 cm² per kilowatt in
excess of 60kW total rated input.
1.2.6 Air Distribution System
VPC units used in buildings having a low heat loss i.e.
where single units are required to cover a large floor area,
and in buildings with high roof or ceiling heights Calecon
thermal economiser units should be fitted to ensure even
heat distribution and minimise stratification.
Care should be taken to avoid impeding the air throw with
racking, partitions, plant or machinery etc.
Care must be taken to ensure that return-air intakes are
kept clear of sources of smells and fumes, and where
there is any possibility of pollution of the air by dust, shavings etc., precautions must be taken to prevent contamination.
If necessary suitable barrier rails should be provided to
prevent any combustible material being placed within
900mm of the warm air outlets.
1.2.7 Electrical Supply
Wiring external to the air heater must be installed in accordance with the I.E.E. Regulations for Electrical Installations and any local regulations which apply. Wiring should
be completed in flexible conduit.
All standard heaters are supplied by 230V - 1N, 50Hz or
400V- 3N, 50Hz depending on the size.
The method of connection to the main electricity supply
must: o Facilitate the complete electrical isolation of the
unit(s)
o Be in a readily accessible position adjacent to
the unit(s)
o Serve only the unit(s)
o Have a contact separation of at least 3mm in all
poles. See the accompanying wiring diagram for
the heater electrical connections.
VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014 Page 7
Page 8 VPC Range Users, Instrucons & Service Instrucons Issue 5.1 Sept 2014
Model
VPC 30
VPC 52
VPC 80
VPC 110
VPC 130
1108
1108
1412
1767
1767
750
750
750
750
750
1676
2132
2132
2043
2209
100
100
130
130
130
265
265
265
265
265
1378
1832
1756
1667
1835
142
142
220
220
220
237
237
237
237
237
286
286
340
340
400
581
581
672
672
788
256
256
308
308
358
657
657
960
1315
1315
650
650
650
650
650
A B C DØ E F G H J J1 K L M
1.3 Size Data
2
2
3
4
3
HEAD
PLAN
Head Plan 2 Head Plan 3 Head Plan 4
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