Powrmatic VPx Series, VPx35, VPx50, VPx120, VPx140 User, Installation & Servicing Manual

...
VPx
Doc Ref: M205 Issue 1.2 Nov 2018
®
User, Installation & Servicing Manual
Issue 1.2 November 2018
ErP COMPLIANT
SEPTEMBER 2018
Certificate Of Guarantee
®
Certificate of Guarantee
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 qualified 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 and qualified 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 certificate
must be kept with the appliance
Failure to provide a copy of the commissioning sheet invalidates the heater warranty
page no. 2 of 40
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
Contents
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 Head Plans 8
1.2 Technical data 9
1.3 General Requirements 10
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 22
2.6 Commissioning and Testing 24
2.7 Servicing 29
Additional Documents
3.1 Fault Finding Flow Chart 32
3.2 Short List of Parts 35
Appendices Information required for ecodesign (ErP) Directive 2009/125 37
Warnings
When working on this appliance the following warnings must be observed:
Danger: Electricity
Warning: Flammable Materials
Warning: Hot Surfaces
Warning: Contains Moving Parts
Read and understand this Service Manual Instructions before operating or servicing this appliance
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
page no. 3 of 40
User Instructions
If the heater has not been left operational proceed as follows.
A) Checks before operating 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 any warm air delivery outlets are open. c) Check that the thermostat is set. d) Check that the clock control is set to an ON period. e) Check that any other controls are calling for heat.
B) Operating the Air Heater
1. Switch on the electrical supply at the isolator
2. If the Red Limit indicator lamp is illuminated, identify the limit stat, remove the black cap and press the reset button.
3. The startup sequence will commence. After a short delay the burners will light and the green ‘ON’ indicator on the front of the heater will be illuminated.
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 lamp on the front of the heater (or on the low level remote reset, or MC200/MC300 if fitted) will be illuminated. To restart the ignition sequence depress the reset button on the low level reset for about 1-2 seconds.
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 'Summer Mode'.
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: 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, controller 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 will light on HIGH FIRE for the first 30 seconds irrespective of the requirements of the external control. The green ‘ON’ indicator will be illuminated. The heater fan will automatically start 30 seconds after the burners light. After the first 30 seconds, the heat output will then be controlled either to high fire or low fire depending on the requirements of the space being heated and the external controls fitted. When the external controls are satisfied the burners will be turned off and 2½ minutes later the heater fan will automatically stop. If the burners fail to light the control box will make another four attempts at ignition before going into burner lockout. The amber ‘Lockout’ indicator/reset switch will be illuminated.
2) Modulating Units
When the burners are alight, the heat output will be controlled to any point between high and low fire; depending on the requirements of the space being heated and the external controls fitted.
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.
4) Overheat Thermostat
This operates if high temperatures within the heater are detected, the burners are turned off and a Red indicator lamp on the front panel is illuminated. VPx35 - 70 units have a single thermostat located inside the heater. VPx90 - 140 units have an additional thermostat on the side of the unit at the opposite end to the controls (either thermostat can go to limit and shut off the burners). The fault condition must be identified and rectified and the thermostat manually reset via the red high limit reset switch. When the unit has cooled, identify the limit stat, remove the black cap and press the reset button. The red indicator lamp will go out and the unit is operational again.
page no. 4 of 40
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
User Instructions
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.
E) Maintenance
To maintain efficient, reliable and safe operation of the heater it must serviced annually by a qualified person.
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 gas supply at the meter 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 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.
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 2018
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.
* Gas Safe Registered Engineer
The VPx range are highly efficient, gas fired, fanned circulation air heaters that cover heat outputs of 35kW to 140kW, have a closed combustion circuit and are supplied complete with a flue system that can be either vertical or horizontal.
VPx heaters are certified for use on Natural Gas, Group H
- G20*. Appliance Categories are Cat II2H (GB, IE). All VPx heaters are CE certified and conform to all the European directives stated in section 1.3.1
VPx heaters are designed to be floor standing and have a centrifugal fan assembly fitted at the base of the heater to circulate the air being heated past the formed tube heat exchanger.
VPx 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.
1.1 Introduction
as defined in BS 5345: Part 2. They are not suitable for siting externally.
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, fan command module and a limit thermostat.
Options include 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 fitted,
adjusted and set in accordance with the data and detail set out in these instructions. If in doubt consult Powrmatic Technical Department.
* LPG conversion kits available.
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
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
page no. 5 of 40
Technical Specification
VPx
Model 35 50 70 90 120 140
Output (nominal)
Input (nett CV)
Air Flow Volume m
Heads 3 4
Airflow
Electrics
Fuel
Overall Dims
Install Clearance
Flue
Combustion Air Spigot mm Ø 100 130
Noise Levels VPx UF dB(A) 60 62 63 68 69 70
Nett Weight VPx UF kg 180 209 287 426 468 542
Throw m 12 22 25 27 30 32
Fan Static
Supply
Connection BSP/Rc ¾"
Nominal Inlet Pressure
Consumption
VPx UF
VPx UF
Diameter mm Ø 100 100 130 130 130 130
Maximum Length
High Fire (max)
Low Fire (min)
High Fire (max)
Low Fire (min)
Standard Pa 250 250 250 180 290 250
Uprated Pa 400 400 400 400 400 400
Standard V/ph/Hz 230/1/50
Optional* V/ph/Hz N/A (400/3/50)
Start Current amp 15.6 26.3 38(18) 34(14) 34(14) 46(29)
Run Current amp 4.7 7.6 11(5.3) 9.8(4.18) 9.8(4.18) 13.1(8.43)
Nat Gas mbar 20.0
LPG mbar 37.0
Nat Gas m
LPG m
Height mm 2184 2286 2381 2607 2607 2722
Width mm 819 819 819 819 819 819
Depth mm 1325 1325 1325 1950 1950 1950
Front mm 1000
Blank Side mm 150 (wall facing side)
Louvred Side mm 500
Rear mm 500
Above mm 1000
Flue Only m 12
Room Sealed m 6
Model 35 50 70 90 120 140
kW 34.0 50.5 70.5 90.0 118.5 137.0
kW 23.8 33.9 47.8 65.3 83.5 93.3
kW 36.5 54.5 76.5 97.5 127.0 146.0
kW 26.08 37.41 52.91 71.65 90.83 101.16
3
/s 1.11 1.51 1.94 2.81 3.56 3.75
3
/h 3.86 5.77 8.10 10.32 13.44 15.45
3
/h 1.52 2.20 3.16 4.01 5.10 5.90
Notes:
Fuel Consumption and input figures based upon nett calorific values as follows: ­Natural Gas (G20) nett CV 34.02 MJ/m
3
MJ/m
Heaters have efficiency levels which meet with the minimum heater efficiency requirements of UK Part L Building Regulations.
VPx heaters comply with the seasonal efficiency and NOx limits
requirements of the Ecodesign regulation (EU) 2015/1188, Directive 2009/125/EC – Lot 21 Tier 1
Standard heaters configured as High/Low. Optional modulation
available.
Air handling data is assessed at room ambient conditions
Throw figures provide the distance to the point where the terminal velocity degrades to 0.25m/s
page no. 6 of 40
3
- Propane (G31) nett CV 88.00
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
Noise levels are applicable to standard VPx models and are measured 5m from appliance in a free field.
Motor kW, run and start amps apply to standard electrical supply as stated. For optional data contact sales office.
Optional 3 phase direct drive centrifugal blowers shown in italics within brackets().
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 VPx Centrifugal units.
1
2
3
4
5
6
7
8
B
M
1
2
Dimensions
VPx
K
COMBUSTION
AIR INLET
0
. 0 5
1 J
EXHAUST AIR OUTLET
J
ØD
ALTERNATIVE FLUE & COMBUSTION AIR
POSITIONS
1 J
H L
G
E
G
J
M
LH
M
C
F
B
Model
A mm 1325 1325 1325 1950 1950 1950
B mm 819 819 819 819 819 819
C mm 1672 1672 1672 1900 1900 1900
mm 100 100 130 130 130 130
E mm 356 356 356 337 337 337
F mm 1314 1314 1236 1547 1547 1547
G mm 142 142 220 220 220 220
H mm 237 237 237 247 247 247
J mm 255 286 345 345 345 400
J1 mm 512 614 709 707 707 822
K mm 207 256 308 308 308 320
L mm 915 915 915 1485 1485 1485
M mm 685 685 685 685 685 685
35 50 70 90 120 140
A
B
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
page no. 7 of 40
Accessories
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
Head Plan 1
(35, 50 & 70)
Head Plan 2
(90, 120 & 140)
Side/rear Inlet Spigots Filters Dampers
0
2
1
0
5
5 8 6
Model
L
35 50 70 90 120 140
5
5 8 6
0
2
7
0
0
6
0
7
69
L
N
L mm 915 1485
N mm 995 1620
P mm 900 1525
Notes -
All dimensions are outside dimensions
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
0
6
1
2
0
0 9 6
0
5
7
9
1
8
1
0 6
0
6 7
0
7
9
6
P
N
16
0
0
6
0
7
9 6
5
2
7
9
1
8
Head Plans
Head Plan 1
(35, 50 & 70)
Head Plan 2
(90, 120 & 140 only)
page no. 8 of 40
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
1.2 Technical Data
Injector Sizes & Burner Pressures - Natural Gas - Group H - G20 Net CV (Hi = 34.02MJ/m³)
(All variants)
Injectors
MODEL No. Size (mm) Marked mbar m³/h mbar m³/ h
VPx35 5 2.26 580 13.2 3.86 5.8 2.76
VPx50 10 2.54 750 9.5 5.77 4.5 3.96
VPx70 10 2.54 750 9.4 8 .10 4.6 5.60
VPx90 8 3.5 150 0 6.0 10.32 3.0 7.5 8
VP x120 10 3.5 1500 6.7 13.44 3.3 9.61
VPx140 12 3.5 1500 6.2 15.45 2.9 10.7
High Fire Low Fire
Burner
Pressure
Gas Rate
Pressure
Burner
Gas Rate
Nominal Inlet Pressure = 20mbar
Minimum Inlet Pressure = 17.5mbar
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
page no. 9 of 40
1.3 General Requirements
1.3.1. Related Documents
All VPx 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
Powrmatic VPx units are designed to operate within an ambient temperature range of -10 to 25°C.
VPx heaters should be located on a solid and level surface. The location chosen must have adequate space for servicing and air circulation around the air heater as well as an adequate air supply.
Consideration should be given to flue routes and points of exit, gas, electrical and control connections. Consideration should also be given to the throw characteristics of the heater, issues of public access and siting of environmental control stations and/or remote temperature sensors where the position needs to be representative of the zone temperature to which they refer.
conditions. Please consult our Technical Department for further information.
1.3.2.1 Sizing of the heater
The heater should be correctly sized for the area that it is heating, Full calculations need to be preformed to ensure the correct KW output heater is fitted (CIBSE elemental methodology can be used, or the Powrmatic Technical Department can provide guidelines).
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)
via a suitable fused isolator (see section 2.4.5 for ratings)
- 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
VPx 90-140 units can also be supplied for 400V 3N, 50Hz.
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.
Heaters should not be installed in hazardous areas or areas where there is a foreseeable risk of flammable or corrosion inducing particles, gases or vapours being drawn into the combustion air or main fan circuits.
Areas where special consideration or advice may be required could include but is not limited to –
Where de-greasing solvents are present, even in minute concentrations
Where paint spraying is carried out
Where styrenes or other laminating products are used
Where airborne silicone is present
Where petrol engine vehicles are stored or maintained
Where dust is present (i.e. wood working or joinery shops)
Where high levels of extract persist.
Installation in such areas may be possible under specific
1.3.4 Gas Supply
A servicing valve and union to facilitate servicing must be fitted to the gas inlet pipe work of the heater. The gas supply must be completed in solid pipe work and be adequately supported.
Heaters suspended by drop rods, straps or chains must have a flexible connection as the final link between the gas supply pipe work and the heater. Sufficient slack must be left in the connection to take account of normal movement of the heater.
WARNING: When completing the final gas connection to the heater do not place undue strain on the gas pipe work of the heater.
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 to suit the building requirements. An existing service pipe must not be used without prior consultation with the local gas undertaking.
page no. 10 of 40
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
1
2
3
4
5
6
7
1.3 General Requirements
1
2
3
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.
1.3.5 Flue System
Only flue systems supplied through Powrmatic Ltd may be used with VPx units. Several configurations of flue and combustion air ducts are available.
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.
Type B22
Installation.
Horizontal Outlet
Type C12 or C32 Installation. Vertical Outlet
Type B22 Installation. Vertical Outlet
VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
Type C12 or C32 Installation.
Horizontal Outlet
page no. 11 of 40
1.3 General Requirements
1.3.6 Ventilation Requirements
Type B flued installations.
Where VPx 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 flued installations.
Where VPx heaters are installed in a plant room or
an enclosure (i.e. 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 flued installations.
Where VPx heaters are Installed within the heated
space (i.e. 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 flued installations.
Where VPx heaters are installed in a plant room or
an enclosure (i.e. 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.
Typ e C
12 or C32 Installation (these refer to section 2.2
of these instructions)
VPx
Input kW
Typ e B22 Installation (these refer to section 2.2 of
these instructions)
Air vents shall be permanently open. In all cases figures are per heater installed. For multi heater installations the appropriate
values for each heater must be added together
In the
heated
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
Air vents shall be permanently open. Figures are for heaters in plant rooms or
enclosures ONLY In all cases figures 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
35 36.5 73.0 146.0 73.0 365.0 182.5 n/a 365.0 365.0 182.5 182.5
50 54.5 109.0 218.0 109.0 545.0 272.5 n/a 545.0 545.0 272.5 272.5
70 76.5 153.0 306.0 153.0 765.0 382.5 n/a 765.0 765.0 382.5 382.5
90 97. 5 195.0 390.0 195.0 975.0 4 87.5 n/a 975.0
975.0 4 87.5 48 7.5
120 127.0 254.0 508.0 254.0 1270.0 635.0 n/a 1270.0 1270.0 635.0 635.0
140 146.0 292.0 584.0 292.0 1460.0 730.0 n/a 1460.0 1460.0 730.0 730.0
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VPx Range Users, Installation & Servicing Instructions Doc Ref M205 issue 1.2 Nov 2018.
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