Powrmatic VPC Series User, Installation & Servicing Manual

Powrmatic
Brand
Powrmatic
Model
VPC Series
Type
User, Installation & Servicing Manual
www.powrmatic.co.uk +44 (0) 1460 53535
[email protected]
Doc Ref: M202 Issue 5.5 Aug 2018
Industrial & Commercial Heating Systems
VPC Gas Cabinet Heater Range
User, Installation
& Servicing Manual
page no. 2 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
Installer
Date:________________Signed: _____________________________________Installer
Commissioned
Date:________________Signed:_______________________Commissioning Engineer
Important: This certicate
must be kept with the appliance
Failure to provide a copy of the commissioning sheet invalidates the heater warranty
----------------------------------------------------
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
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.
page no. 3 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.
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
Users, Installation and Servicing Instructions
CONTENTS
page no. 4 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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.
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.
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.
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.
User Instructions
page no. 5 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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 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.
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
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.
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.
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.
1.1 Introduction
page no. 6 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
Model 30 52 80 110 130
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
Airflow
Heads m 3 3 4 4 4
Throw m 12.0 22.0 21.0 26.0 27.0
Fan
Static
Standard Pa 150 200 225 150 200
Uprated (Refer to Powrmatic)
Electrics
Supply Standard V/ph/Hz 230/1/50
Optional V/ph/Hz n/a 400/3/50
Std
Fan
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
Fuel
Connection BSP/Rc ¾”
Minimum Inlet
Pressure
Nat Gas mbar 17.5
LPG mbar 37.0
Consumption 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
Overall
Dims
UF Upright
Freeblow
Height mm 2272 2713 2804 2715 2998
Width mm 750 750 750 750 750
Depth mm 1108 1108 1412 1767 1767
Install
Clearance
UF Upright
Freeblow
Front mm 1000
Blank mm 150
Louvred mm 500
Read mm 500
Flue
Diameter mm Ø 100 130
Max
Length
Flue Only m 12
Room Sealed m 6
Combustion Air Spigot mm Ø 100 130
Noise Levels dB(A) 60 68 76 72 74
Nett Weight kg 178 248 305 362 410
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
VPC UF / VPC UD
Duties
page no. 7 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
Model A B C D E F G H J J1 K L M Head
Plan
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
G
H
50
G
H
Ø D
GAS ENTRY
COMBUSTION
AIR INLET
EXHAUST
AIR OUTLET
ALTERNATIVE FLUE
& COMBUSTION AIR
POSITIONS
J 1
JJ
J 1
K
BAB
C
M
E
L
L
M
M
F
Dimensions
page no. 8 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
650
750
760
660 760
660
136 SIDE REAR
N
L
136
185 SIDE REAR
760
660
N
L
185
760
660
650
750
660
650
L
660
50
50
SIDE REAR
Side/Rear Inlet Spigot Side/Rear Filters
Model 30 52 80 110 130
L 657 960 1315
N 757 1060 1415
Side/Rear Dampers
Head Plan 2 Head Plan 3Head Plan 1
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
Head Plans
Accessories
page no. 9 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
High Fire Low Fire
Injectors Burner
Pressure Gas
Rate Nominal
CO
Nett Flue
Temp Burner
Pressure Gas
Rate Nominal
CO
Nett Flue
Temp
MODEL No. Size (mm) Marked mbar m/h %°C mbar m/h %°C
VPC30 61.94 194 13.8 3.45 8.6 171 4.6 1.90 3.7 125
VPC52 12 1.94 194 10.4 5.98 8.2 172 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 - Natural Gas - Group H - G20 Net CV (Hi = 34.02MJ/m³).
Minimum Inlet Pressure = 17.5mbar
High Fire Low Fire
Injectors Burner
Pressure Gas
Rate Nominal
CO
Nett Flue
Temp Burner
Pressure Gas
Rate Nominal
CO
Nett Flue
Temp
MODEL No. Size (mm) Marked mbar m/h %°C mbar m/h %°C
VPC30 61.36 136 21.7 1.33 11.0 170 7.0 0.74 4.6 125
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
Injector Sizes & Burner Pressures - Propane G31 Net CV (Hi = 88.00MJ/m³).
Minimum Inlet Pressure = 37mbar
MODEL Electrical
Supply Motor
kW Nominal
Motor R.P.M. Max Fan
Amps (A) Start Amps
(A) Run Amps
(A) Fuse Rating
(A)
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
High Fire Low Fire
Air Volume Maximum
Duct
Resistance
Fan
Motor Noise
Level Weight
Input
(Nett) Output Input
(Nett) Output
MODEL kW kW m/s m/h Pa kW dB(A) kg
VPC30 32.6 30 18.0 15.7 0.8664 3119 150 0.55 68 178
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
Electrical Loadings - 1Pha
Heater Specications
1.2 Technical Data
page no. 10 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
Motor (a) Motor Pulley (b) Motor Pulley
TaperLock (c) Centrifugal Fan (d)
kW Pha RPM Pt no. Size Pt no. Size Pt no.
type
Size Pt no.
VPC30 0.55 1940 n/a n/a n/a n/a n/a 1321 x 321 1402CFAN280/T/15
VPC52 1.1 1940 n/a n/a n/a n/a n/a 1321 x 321 1402CFAN210/T/15
VPC80 1.4 1940 n/a n/a n/a n/a n/a 1381 x 381 1402CFAN580/T/15
VPC110 1.5 11500 140001908 95x1SPA 142000602 1210-24 142003350 2321 x 321 1402CFAN240/T/2DECK
VPC130 2.2 11500 140001998 100x1SPA 142000601 1610-28 142161028 2321 x 321 1402CFAN240/T/2DECK
VPC110 1.5 31500 140001915 95x1SPA 142000602 1210-24 142003350 2321 x 321 1402CFAN240/T/2DECK
VPC130 2.2 31500 140002000 100x1SPA 142000601 1610-28 142161028 2321 x 321 1402CFAN240/T/2DECK
Drive Data - Standard Motor
Fan Pulley (e) Fan Pulley
TaperLock (f) Belt(s) (g) Contactor/Relay Overload
Size Pt no. Size Pt no. Size Pt no. Type Pt no. Type Pt no.
n/a n/a n/a n/a n/a n/a 5.5kW AC3 143000601 7-11A 143000801 VPC30
n/a n/a n/a n/a n/a n/a 5.5kW AC3 143000601 7-11A 143000801 VPC52
n/a n/a n/a n/a n/a n/a 7. 5kW AC3 143000600 7-11A 143000801 VPC80
170x1SPA 142001689 1610-25 142003370 A990/38 142109801 7.5kW AC3 143000600 7-11A 143000801 VPC110
180x1SPA 142001675 1610-25 142003370 A1050/40 142110507 7.5kW AC3 143000600 12-18A 142000800 VPC130
160x1SPA 142001619 1610-25 142003370 A990/38 142109801 7. 5kW AC3 143000600 7-11A 143000801 VPC110
180x1SPA 142001675 1610-25 142003370 A1050/40 142110507 7.5kW AC3 143000600 5-8A 142000802 VPC130
a
b
c
d
e
f
g
Fan type 2Fan type 1
page no. 11 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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.
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 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.
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
1.3 General Requirements
page no. 12 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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. 13 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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
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.
VPC Input
kW
In the
heated
space
In a plant room,
ventilation to
outside
In an enclosure,
ventilation to
outside
In the
heated
space
Ventilation is to a
room or internal
space
Ventilation is to a
outside air
Low level
grille. Free
area cm²
Low level
grille. Free
area cm²
High level
grille. Free
area cm²
Low level
grille. Free
area cm²
High level
grille. Free
area cm²
Free area
grille cm²
Low level
grille. Free
area cm²
High level
grille. Free
area cm²
Low level
grille. Free
area cm²
High level
grille. Free
area cm²
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
1.4 Ventilation Air Requirements
page no. 14 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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
* 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
AE* B
Minimum Clearance Distance
D*
C
2.1 Fitting the Unit
page no. 15 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.
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.
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.
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.
page no. 16 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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.
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.
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.
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.
2.2 Flue/Combustion Air Duct System
page no. 17 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
6m maximum
Terminal
Lengths
Adjustable
lengths
Single to twin
adaptor
Flashing
Flue socket
Combustion air
socket
Condensate drain
length
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.
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.
Fig 1b Exhaust only system - horizontal
Type C12 installation
Terminal
Lengths
Adjustable
length
Single to twin
adaptor
Flue socket
Combustion
air duct
6m maximum
Combustion
air socket
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
12m maximum
Terminal
Lengths
Adjustable
length
Flashing
Flue
socket
OPTION 1
Combustion air entry
(fitted with inlet grille) Condensate drain
length
OPTION 2
Combustion air entry
(fitted with inlet grille)
page no. 18 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
Fig 2b Individual system - horizontal
Type B22 installation
Terminal
Lengths
Adjustable
length
Flue
outlet
OPTION 2
Combustion air entry
(fitted with inlet grille)
12m maximum
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.
FAN / LIMIT THERMOSTAT
EXHAUST FAN
PRESSURE SWITCH
GAS VALVE
MANUAL OVERRIDE SWITCH
BURNER RESET
HIGH LIMIT RESET
CONTACTOR
OVERLOAD
MC200 CAB
2.3 General Identication of Electrical Items
page no. 19 of 40
VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
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.
Model Phase Running
Amps (A)
30 14.4
52 14.5
80 19.4
110 19.3
130 110.7
110 33.4
130 34.5
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
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
2.4 Electrical Cable Installation
page no. 20 of 40 VPC Range Users, Installation & Servicing Instructions Doc Ref M202 issue 5.5 Aug 2018.
VPC 30-80 On/O Gas Cabinet 1Pha
EARTH
NEUTRAL
LIVE
MAINS SUPPLY
L LL
L
EE
E
ENN
N
N1
1
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 / 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 Board
N. Internal Lockout Reset Button
O. Jox Relay
P. Engineers Override Switch
Q. MC200 Fuel Saver
R. Powrtrol Remote Reset
S. Ktec Contactor
T. Otec Overload
U. Jox Relay
145030844
143000306
143070274
Model specific
Model specific
Model specific
Model specific
143100603
147600101
Model specific
142423003
143000526
142403600/2
143070274
143000816
143100663
MC200BL
POWRTROL/RR
Model specific
Model specific
143000816
L
10
10
E
F
2
2
3
3
4
4
5
5
6
6
7
7
7
7
8
8
8
8
9
9
11
11
12
12
13
13
14
14
15
15
H
I
1234567
8
9
10
11
12
4A
FUSE
16171819131415
J5
J6
JT2
JT1
BRAHMA
CODE 3756400
Type DMN32
NOTES
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
Main Fan Only 230V Input
Lockout Indicator 230v Output
Lockout Reset - Neutral Switch
External Controls
Connections
B
°
C°
C
5 Core
Cable
Yel 0.5
Wh 0.5
Or 0.5
Br 0.5
Blu 0.5
Br 0.5
Blu 0.5
Wh 0.5
Blk 0.5
Or 0.5
Br 0.5
Blu 0.5
Gry 1.0
Br 1.0
Blk 1.0
Yel 1.0
Or 0.5
Or 0.5
Blk 0.5
Wh 0.5
Blu 0.5
Wh 0.5
Blu 0.5
A
J
K
MC200 fuelsaver
SEN 1
COM
IN 2
0-10v +
0-10v -
Reset
Lockout
Heat Hi
In
Heat Hi
Out
Heat Lo
In
Heat Lo
Out
Fan In
Fan Out
L Out
N
E
L
Q
LN2156
NVx Terminal Numbers
L/O
Reset
L/O
LAMP
CLOCK
O/P
HEAT
IN
HEAT
OUT
L
N
POWRTROL RR
VENT
VENT
65 21
NVx Terminal Numbers
R
N L
Heat Demand 230V Input
Br 0.5
Blu 0.5
Br 0.5
Blu 0.5
LIMIT
FAN
ºc
White Rodgers
alternative stat
(143000307)
Note:
Fan Stat - Right Hand Side
Limit Stat - Left Hand Side
16
15
8
13
L3
L2
L1
14
T3
T2
T1
A1A29596
T1
T2
T3
G
3 Core
Cable
S
T
Blk 1.5
Br 1.5
Blu 1.5
Br 1.5
Br 1.5
Blu 1.5
Gr/Yel 1.5
Br 1.5
Gr/Yel 1.5
4 Core
Cable
Br 0.5
16
16
17
17
D
NCNOC
C
M
18
18
19
19
20
20
21
21
Br 1.0
Blk 1.0
Blu 1.0
Gry 1.0
6
5
4
2
3
1
10
9
11
87
NO
COM
NC
R/S
TRP
N
L
Blu 0.5
Gry 0.5
Blk 0.5
Br 0.5
Or 0.5
Blu 0.5
Note:
Remove Mode Link 'B'
Br 0.5
Or 0.5
Br 0.5
COM
NO
NC
U
Br 0.5
Blu 0.5
NOTES
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.
2.5 Wiring Diagrams
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Powrmatic VPC Series User, Installation & Servicing Manual

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Powrmatic
Model
VPC Series
Type
User, Installation & Servicing Manual
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