Powrmatic VPx Series, User, Installation & Servicing Manual

Page 1: ...w w w p o w r m a t i c c o u k VPx User Installation Servicing Manual Issue 1 2 November 2018 Doc Ref M205 Issue 1 2 Nov 2018 ErP COMPLIANT S E P T E M B E R 2 0 1 8 ...

Page 2: ...ns 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 qu...

Page 3: ... 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 Users Installation and Servicing Instructions CONTENTS Contents When working on this appliance the following warnings must be observed...

Page 4: ...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 st...

Page 5: ... 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 Europ...

Page 6: ... Length Flue Only m 12 Room Sealed m 6 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 Model 35 50 70 90 120 140 Notes Fuel Consumption and input 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...

Page 7: ...60 53535 Fax 01460 52341 Web www powrmatic co uk E mail r d powrmatic co uk POWRMATIC LTD 01 NEW DRAWING 22 08 2018 chrisbromfield TITLE DESCRIPTION DRAWING NUMBER MATERIAL GAUGE SPEC SALVAGNINI MATERIAL REQUIRED PROJECTION UNITS B C 50 0 F G A B M L H E G H L M ØD ALTERNATIVE FLUE COMBUSTION AIR POSITIONS EXHAUST AIR OUTLET COMBUSTION AIR INLET J1 J J1 J K 2 3 4 5 6 7 8 A B C D Title Here VPX Dim...

Page 8: ...aterial Gauge Spec Here ISS MODIFICATIONS DATE DCR I A DRN UNSPEC TOLS Hole centers 0 1mm General 0 1mm Finished sizes 0 1mm MM DO NOT SCALE This drawing is copyright and the property of POWRMATIC LIMITED It must not be used without their knowledge nor communicated to any other person or company Powrmatic Ltd Hortbridge Ilminster Somerset TA19 9PS Tel 01460 53535 Fax 01460 52341 Web www powrmatic ...

Page 9: ...e mm Marked mbar m h mbar m 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 1500 6 0 10 32 3 0 7 58 VPx120 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 Injector Sizes Burner Pressures Natural Gas Group H G20 Net CV Hi 34 02MJ m Nominal Inlet Pressure 20mbar Minimum Inlet Pressure 17 5mbar 1 2 Technica...

Page 10: ... 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 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 c...

Page 11: ...22 Installation Vertical Outlet 1 3 General Requirements Type B22 Installation Horizontal Outlet Type C12 or C32 Installation Vertical Outlet Type C12 or C32 Installation Horizontal Outlet 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D E E F F Title Here SCALE 1 15 VPX Flue Arrangements SHEET 1 OF 1 Description Here ISS DATE DCR Material Gauge Spec Here MODIFICATIONS I A DRN UNSPEC TOLS Hole cent...

Page 12: ...s required These being Natural Ventilation Grilles having a free area of at least 2cm 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 flue...

Page 13: ... s must be provided If the air heater s are installed in a plant room the return air intake s and the warm air outlet s from the heater s must be fully ducted into and out of the plant room to avoid interference with the operation of the heater The openings in the structure of the plant room enclosure through which the ducting passes must be fire stopped Care must be taken to ensure that return ai...

Page 14: ...est obstacle Distance A Front mm 1000 B Rear mm 500 C Above mm 1000 D Side adjacent to wall mm 150 Opposite Side mm 500 VPx UF Side View D D B A C Note The minimum clearances must be observed for installation and servicing Warning 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 Note The acc...

Page 15: ...s 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...

Page 16: ...b 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 ...

Page 17: ...he 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 similar 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 adapter to the terminal section and then extend down to the heater using straight lengths Fit ...

Page 18: ...e 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 The condensate drainage pipe should be run in a standard drain pipe material and have a fall of at least 2 5 in every 50m Copper or copper based alloy shall not be used for condensate drains Se...

Page 19: ...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 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...

Page 20: ... 4 2 5 6 VPx120 9 8 15 16 4 2 5 6 VPx140 13 1 15 16 8 5 10 10 2 4 3 Wiring 2 4 4 External Fuses 2 4 Electrical Cable Installation The wiring terminals are located on the electrical panel behind the side door of the heater which firstly has to be opened L N E L3 N E L2 L1 Mains input of either 230V 50Hz 1Ph or 415V 50Hz 3Ph supply connections are via a separate terminal block For input power refer ...

Page 21: ...lation terminal 10 Live to Controller terminal 11 Neutral to Controller terminal E Earth to Controller 3 4 5 6 7 8 2 11 1 9 10 N L E N 230v Supply for Controller L Modulating Modulating 0 10v Lockout Reset Lockout Indication N O The 230v in Accesso 230v in High Fire Call for Fan Only 230v Out Call for Heat Momen 230v ou Heat On Signal 230V Output 230V Input 230V Fan Only Signal 230V Live Output Ne...

Page 22: ...018 2 4 6 Interconnecting Wiring 2 4 6 1 VPx High Low to Remote MC200 2 4 6 2 VPx Modulation to Remote MC200 Warning External controls MUST be powered via heater terminal 10 11 and Earth Warning External controls MUST be powered via heater terminal 10 11 and Earth 2 4 Electrical Cable Installation ...

Page 23: ...5 Wh G Y 1 0 Or 1 0 Blu Grn Grn Blu Yel Wh 7 8 Br Blk Wh Blu Br Blu Hi Lo Gas Valve Head Blu 1 0 Vi N SW TR L GV PACTROL NC NO C FAN COMMAND MODULE MKIII C A B 2 1 C LIMIT STAT1 2 1 C LIMIT STAT2 Red Neon Terminal 1 Stat extension connections when secondary stat is fitted Pactrol Engineer s Switch if fitted Brn Blk Gry Grn Yel L N E E N L N L E GREEN NEON RED NEON Grn Red Gry Wht Heat Aux 230v out...

Page 24: ...m assembly Wiring Legend 2 Wire size 0 5mm Wire size 1 0mm 2 Loom sub assembly GAS VALVE AMBER INDICATOR RESET LIMIT STAT FAN EXHAUST MAIN FAN S L 18 17 16 15 14 13 AIR PRESSURE SWITCH MG V DR IV E R Red Blk Vi Wh G Y 0 5 Grn G Y 0 5 Grn Red Gry Blu Blu Vi Or Blu 1 0 Or 1 0 Br 1 0 G Y 0 5 G Y 1 0 V i Blk 0 5 G Y 1 0 Blu Or 1 0 Blu Grn Grn Blu Yel Wh Male Bullet connector Female Spliced connection ...

Page 25: ...that the control is set to winter operation 2 6 5 Operating the Air Heater NOTE On initial lighting of the heater s it may take some time to purge the internal pipe work of air IMPORTANT The internal pipe work of the appliance has been tested for soundness before leaving the factory After establishing the main burners test round the gas inlet connection using a leak detection fluid 1 Switch on the...

Page 26: ...n the data plate In addition it is advisable to check the gas rate using the gas meter dial pointer ensuring that no other appliances supplied through the meter are in operation dial pointer ensuring that no other appliances supplied through the meter are in operation 3 Repeat 2 above with external controls set to maintain low fire 4 If it is necessary to adjust either the high fire or low fire pr...

Page 27: ...e pressure gauge and replace the sealing screw 2 6 6 1 3 Modulating Control Board For Modulation a modulating control board is fitted which also includes the fan command outputs The board interfaces between a 0 10VDC control signal and the modulating regulator Basic operation method 1 With the 0 to 10 signal at 0 the gas valve drive signal will be de energised 2 When the input control signal goes ...

Page 28: ...ermostats are wired in series either thermostat will shut down the burner 2 6 7 Air Heater Controls 1 Close the gas service tap and ensure that the gas valve is heard to close within 1 second and that the lockout light is illuminated Note that the heater may attempt five re ignitions before going to lockout Open the gas service tap and reset the unit from lockout 2 Check that the room thermostat a...

Page 29: ... 7 4 Exhaust Fan 1 Remove the four screws securing the flue outlet socket 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 safet...

Page 30: ...t Powrmatic 2 7 6 1 Multifunctional Control 1 Ensure that the gas service valve is turned OFF If a flexible gas connection has been used go to step 2 otherwise unscrew the union nut situated immediately downstream of the gas service valve 2 Remove the electrical plug connections from the top of the multifunctional control 3 Release the flanged connections at the inlet and outlet of the multifuncti...

Page 31: ...he air pressure switch 4 Remove the screws fixing the air pressure switch and remove switch 5 Fit replacement in reverse order refitting the sensing tube to the negative or L tapping on the pressure switch 6 Adjust pressure switch set point to that shown in the following table Model Pressure Switch Setting Pa LNVx35 146522176 180 LNVx50 180 LNVx70 200 LNVx90 146522177 300 LNVx120 350 LNVx140 330 2...

Page 32: ...Is there 230V between Pactrol controller terminals CON5 pin 1 and pin 2 START YES YES YES Is the unit in overheat trip RED lamp will be indicating NO No call for heat Check controller Is there 230V at contractors terminal 1 Is the exhaust fan running NO Is there 230V on the WHITE cable to the N O terminal of the Pressure switch Replace Pactrol YES NO Is there 230V on the YELLOW cable to the C term...

Page 33: ...as a good earth Check cable to Pactrol NO Replace Electrode YES YES Is the flame sensor sending a rectification signal back to the controller Ensure there are no cracks on the ceramic Clean electrode with wire wool Ensure mains polarity is correct Check cable to Pactrol Has the flame rectified NOW Check flame current by connecting a sensitive multi meter capable of measuring micro amps Minimum rea...

Page 34: ...rrect setting Check Overheat Stat for incorrect limit setting Check fan rotation Remove the black cap and press the reset button Replace Limit Stat YES Continued from previous page Has the main fan started NOW Burner STILL in high limit trip YES 3 1 1 Modulation Driver LED Indication The unit will have a single LED indicator and will provide the following information Steady on LED Unit in standby ...

Page 35: ... 50 145035208 KIT Gas Valve VR4605AB 70 90 145035204 KIT Gas Valve V425AB 120 140 141378715 KIT Ignition Electrode 35 70 90 140 142423010 142423004 Rectification Flame Sensor Probe All 142423003 Burner 35 70 90 140 142400240 142400241 Limit Stat All 142403609 Control Box Sequence Controller All High Low All Modulation 145030846 145030847 High Low Governor Head 35 140 HL 142466402 3 2 List of Parts...

Page 36: ...kIII All except MOD 142403603 Pressure Switch HUBA 604 35 70 90 140 146522176 142522177 Exhaust Fan Exhaust Fan c w Mounting Brackets 35 50 35 50 140210496 NVX1050EXH SP Exhaust Fan Exhaust Fan c w Mounting Brackets 70 70 140201505 NVX6075EXH SP Exhaust Fan Exhaust Fan c w Mounting Brackets 90 140 90 140 140201506 NVX90140EXH SP Main Centrifugal Blower VPx 35 50 90 70 120 140 tba 1402CFAN210 T 15 ...

Page 37: ... Loss Factor N A N A N A Emission Efficiency hs flow 93 93 93 Seasonal Space Heating Energy Efficiency hs h 72 1 73 7 73 7 Model 35 50 70 Rated Heat Capacity kW 36 5 54 4 76 5 Low Heat Input Nett CV kW 26 1 37 4 52 9 Minimum Heat Capacity kW 23 8 33 9 47 8 Useful Efficiency High Fire 93 93 92 Low Fire 91 91 90 Electrical Power Consumption High Fire kW 0 07 0 06 0 06 Low Fire kW 0 07 0 06 0 06 Stan...

Page 38: ...page no 38 of 40 VPx Range Users Installation Servicing Instructions Doc Ref M205 issue 1 2 Nov 2018 Notes ...

Page 39: ...page no 39 of 40 VPx Range Users Installation Servicing Instructions Doc Ref M205 issue 1 2 Nov 2018 Notes ...

Page 40: ...ht Dublin 24 tel 353 0 1452 1533 fax 353 0 1452 1764 e mail info powrmatic ie web www powrmatic ie Getting In Touch Powrmatic pursues a policy of continues improvement in both design and performance of its products and therefore reserves the right to change amend or vary specifications without notice Whilst the details contained herein are believed to be correct they do not form the basis of any c...