NV Installation Manual Issue 3.6 July 2009
Contents
1. flue positions B m n 120 G 455 D E Front Side NV60 D SHOWN Alternative 700 J flue positions F A i Front T Alternative flue positions NV140 F SHOWN Top Em 1 ZEE Flue J L mm E Bas d 192 109 502 Ind 189 120 262 5 510 EN NV25 151 1000 506 176 116 181 a 227 E 738 172 5 142 236 5 100 83 NV50 970 NV60 818 738 Nveo 740 aues 146 798 NV75 890 258 202 220 NV120 870 2345 870 244 5 1948 2014 88 fero Ei NV140 1035 HIGHFIRE LOWFIRE INPUT INPUT VOLUME DUCT MOTOR WEIGHT Table 2 Specifications qw m8 Lm e em oh Ht e d em o e re on pne m onm fee ws oo fo fae NV35 quee rera pem pons noos FMA asco 55 NV40 wa 5 4545 499 2419 2122 10405 238 na 1685 114 eee NV 54 23 50 0 28 40 24 83 1 3006 ETT TE xam 130 pase cum s 250180 O NA LEI 9525 58 50 54 50 2 32. 9 Fault Finding Flow Chart START Gas amp Electrical Turn supplies on Yes supplies present at heater ce Check fuses connections 230V at Heat terminal Check control circuit Time clock thermostats calling for heat Yes Voltage at limit stat 1 on PCB No Check Fuse 1 Ok Faulty PCB Yes Failed Replace Voltage at limit stat 2 on PCB No Check limit stats reset manual stat Check connections Yes Exhaust fan runs No Check fuse 2 __ Failed Replace Yes Ok 230V to air pressure Lock out light on Faulty PCB after 3 secs switch common Exhaust fan runs Yes Faulty gas valve Check replace ae re pow No 230V resistor 470k 0 6w 1 on PCB Yes Yes between gas valve 2 live amp neutral Pressure switch sensing Replace exhaust pressure Adjust set 230V to air pressure No int repi fan switch N O Check pressure sensing tube Adjust pressure switch set point Yes Change pressure switch No L 1 No Gas valve opens 230V t
3. gt J powrmatic The NV Range Users Installation and Servicing Instructions TESTED STAGE 1 rn mechanical construction assembly nd electrical sequence che ck STAGE 2 Full functional test in accordance with Quality System Procedures Heater Model Heater Serial No Type of Gas WARNING THIS APPLIANCE MUST BE EARTHED 4 00 When supplied separately NV Range Users Installation amp Servicing Instructions Issue 3 6 July 2009 45 powrmatic Certificate of Guarantee Dear Customer This is to certify that this appliance is guaranteed for two years including parts and labour from the date of original commissioning The heat exchanger where fitted is guaranteed parts only for a further eight years chargeable on a sliding scale basis price relative to age 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 3 As much detail as possible on the fault Your supplier or installer will then contact Powrmatic to make a guarantee claim on your behalf Conditions of Guarantee 1 The appliance must have been installed by a competent recognised installer and in accordance with the manufacturers instructions building regulations and local regulations 2 The appliance has been professionally commissioned 3 The appliance has been maintained on
4. 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 Switch on the electrical supply at the isolator and the 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 burners fail to light the control box will go to lockout and the lockout light on the low level remote reset will be illuminated To restart the ignition sequence depress the reset button on the low level reset for about 5 seconds If the unit will not light after four or five attempts then shut down the unit and call in a service engineer 3 To Shut Down the Air Heater 3 1 For Short Periods Turn the room thermostat to the OFF or lowest setting 3 2 For Long Periods Complete step 3 1 above Wait for 5 minutes and then turn OFF the electrical supply at the isolator 4 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 41 Standard Units The ignition sequence will commence each time that the external controls e g Timeclock room thermostat etc call for heat The heater fan will automatically start between 0
5. 141378715 142423002 142423004 142423003 142400240 142400241 142403609 143000310 142403610 3 142466402 142466403 142400305 140210499 140201505 140201506 146522174 143016131 BSI Registered Firm FM 414 Ind amp Comm Air Heaters BSI Air Moving Equipment Flues amp Chimneys Natural J Smoke amp Heat Ventilators Powered Supply amp Extract Fans amp Systems 150 9001 HEATING DIVISION Hort Bridge Somerset 19 9PS Tel 01460 53535 Fax 01460 52341 Every effort is made to ensure accuracy at time of going to press However as part of our policy of continual product improvement we reserve the right to alter specifications without prior notice
6. 7 6 Replacement of Faulty Components 7 6 1 Multifunctional Control 1 Remove the burner assembly as previously described in Section 7 2 2 Release the flanged connections at the inlet and outlet of the multifunctional control and remove the multifunctional control 3 Reconnect the new valve in the reverse order to that above ensuring that the valve is correctly orientated Renew the sealing O rings if necessary 7 6 2 Burners Remove the burner assembly as described in Section 7 2 2 Remove the end plates of the burner assembly and the central burner support plate 3 Exchange burners as required and reassemble components in reverse order 4 Re commission the appliance as described in Section 6 7 6 3 Electrode Assemblies 1 Disconnect the electrode leads from the pcb terminal as appropriate 2 Remove the screw securing the electrode assembly to the burner assembly side plate and withdraw the assembly 3 Fit replacement and reassemble in reverse order Check that 12 the spark gap is 2 5mm See Fig 8 and the rectification electrode is 10 12mm forward of the burner 7 6 4 Limit Thermostat NB Ensure that the thermostats are set correctly before fitment Limit Thermostat settings NV 10 25 140 90 NV 15 and 20 100 C NV 35 110 C 1 Remove the screws securing the thermostat phial mounting plate to the inner bulkhead withdraw assembly and unclip the phial 2 Remove the electrical connections from
7. 98 239 Nvi20 8 210 210 270 517 100 309 NV140 10 2 10 210 26 1 6 09 9 5 4 04 Table 4 Electrical Loadings 1ph 10 25 25 25 36 25 25 55 Models Centrifugal Fan Sections NOMINAL PLATE FUSE NOMINAL PLATE FUSE MODEL MOTOR AMPS AMPS AMPS RATING MOTOR AMPS AMPS AMPS RATING R P M A A A A R P M A A A A NViO 900 048 0 34 0 16 2 5 Note 3ph Data is E units ordered to this NV50 3 ENEHES 820 3 General Requirements 3 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 amp 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 pipework 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 precau
8. handling units and NV EA units are for siting externally Heaters are fitted as standard with atmospheric inshot burners a fully automatic control for ignition flame sensing gas supply control and safety functions an internal exhaust fan main air fan F and C models fan timer high temperature thermostat and limit thermostat Options include HIGH LOW or modulating burner controls inlet duct connection outlet duct connection 45 head 90 outlet bend vertical horizontal outlet louvre assembly and a full range of modular duct components Gas Safety Installation amp Use Regulations It is law that all gas appliances are installed adjusted and 1f 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 2 TECHNICAL DATA E 10mm Suspension Points Alternative N flue positions J oo B 120 G H 455 F A L z n D Front Side Top NV20 D WITH CENTRIFUGAL FAN SILENCER SECTION SHOWN Alternative
9. Individual system horizontal Individual system vertical Controls Layout Governor adjustment Honeywell VR425A Governor adjustment Honeywell VR4605A High Lo Regulator Modulating Regulator Ignition Electrode Spark Gap 1 INTRODUCTION The NV range are highly efficient gas fired fanned circulation air heaters that cover heat outputs of 10kW to 140kW have a closed combustion circuit and are supplied complete with a flue system They are certified for use on Natural Gas Group H G20 and Propane G31 only Appliance Categories are Cat II2H3P GB IE The heaters are designed to be suspended from suitable roof points or alternatively to be mounted on purpose designed brackets and are intended primarily for heating commercial or industrial premises 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 NV F heaters have an axial fan assembly fitted at the rear to circulate the air being heated through the folded tube heat exchanger NV C units are supplied with a centrifugal fan silencer duct section and NV D units for use with ducted systems where the air moving fan is by others or a centrifugal fan section is used remote from the heater NV DH units are for use in air
10. a yearly basis by a competent servicing company 4 The appliance has been used in accordance with the manufacturers instructions 5 The correct specification fuel has been used 6 No unauthorised repairs or modifications have been made 7 Powrmatic General Conditions of Sale 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 respect of any claim for direct or indirect consequential losses including loss of profits or increased costs arising from loss of use of the appliance 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 Important This certificate must be kept with the appliance Users Instructions 1 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 15 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 f Ensure that the Summer Winter switch is in the Winter position g Check that the overheat reset button has not operated 2 Lighting the Air Heater NOTE
11. adjustment screw under cover cap gt Honeywell VR4605A B1027 NV NV NV NV NV NV NV NV NV NV NV NV NV Model 10 15 20 25 30 35 40 50 60 75 90 120 140 Natural Gas G20 High Fire CO2 6 7 7 3 7 4 7 39 7 8 8 25 7 7 8 7 8 1 8 8 7 4 8 7 8 3 Low Fire CO2 3 7 3 1 3 2 3 7 3 7 3 6 3 6 3 5 3 4 3 6 3 9 4 4 4 6 Propane G31 High Fire C02 7 3 7 9 8 5 8 1 9 1 9 2 9 3 9 5 9 1 9 7 8 5 10 1 8 0 Low Fire CO2 4 1 3 8 3 7 4 1 4 1 3 9 4 3 4 0 3 9 4 1 4 5 5 0 4 0 10 Reconnect high low regulator and check high fire pressure Repeat from step 1 if necessary v Replace cover cap 5 Turn off the main burner as in 6 5 1 disconnect the pressure gauge and replace the sealing screw Turn on the main burner as in 6 5 1 and test for gas soundness around pressure test joint using a leak detection fluid Replace access panel 6 6 1 3 Modulating Regulator 1 Set external controls to ensure that the main burner is off Remove the side access panel Connect a pressure gauge to the burner pressure test point on the multifunctional control 2 Set external controls so as to turn on the main burner and maintain high fire Compare the measured burner gas pressure to that stated on 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 3 Repeat 2 above with external controls set to maintain low fire 4 If it is necessary to adju
12. five pcb mounting posts squeeze in the retention tag and release the pcb When all five have been released remove the pcb from its five mounting posts 3 Fit replacement in reverse order 7 6 8 Centrifugal Fan Motor 1 Disconnect the electrical connections to the centrifugal fan section 2 Remove the side panels of the section for access to the fan and motor 3 Fit replacements as appropriate and reassemble in reverse order Note If a 3ph motor is being replaced ensure that the direction of rotation is correct If it is not interchange any two of the three phases connected to the motor 8 Connections to External Controls Note To achieve maximum system efficiency it is recommended that NV units are controlled by an MC200 Fuel Saver unit Simple room thermostat and room thermostat timeclock control systems will not provide optimum system efficiency and fuel savings HEAT L O E amp x lt lt NEUTRAL LN gt gt z Z Remote Sensor Remote Sensor 2 _ optional optional 1 1 SEN 1 1 4 SEN 1 1 4 4 2 4 4 COM 2 IN 2 3 2 3 0 10V 8 4 0 10 8 4 5 5 m 12 5 m RESET 6 gt RESET 6 gt Lockout 7
13. seconds the ignition spark will be generated and the main gas valves energized The burners will then light 2 If the burners fail to light the control box will go to lockout and the lockout light on the internal pcb will be illuminated To restart the ignition sequence depress the reset button adjacent to the lockout light for about 5 seconds Note A secondary red LED mounted on the pcb surface signals as follows a 1 flash at power up as voltage is stabalising b 1 Hz flash signals safety shut down or over voltage greater than 260V If the heater is running and the air pressure signal is lost the LED will flash at 1Hz If the air pressure signal then re establishes the unit will restart after approximately six minutes If when the air pressure signal 15 lost the unit is turned off and then back on the normal startup sequence will take place c 2Hz flash signals undervoltage less than 200V 3 SHUT OFF Switch OFF the electrical supply to the heater or set the clock control to OFF or set the room thermostat to MIN 6 6 Adjustments 6 6 1 Burner Gas Pressure This 1s set for the required heat input before despatch In the case of Hi Lo and Modulating units both high and low pressures are set Pressures should be checked in the following manner 6 6 1 1 Standard Units 1 Set external controls to ensure that the main burner 15 off Open the side access door Connect a pressure gauge to the burner pressure test point on the multifuncti
14. 30seconds depending on the setting of the internal timer after the main burners light 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 42 High Lo amp 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 external controls fitted 4 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 5 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 6 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 DO NOT USE A NAKED FLAME and contact the local gas undertaking immediately Powrmatic heater
15. 4 5 cm 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 270cm plus 2 25 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 communication with the outside air is possible only by means of high level air vents 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 9cm per kilowatt of rated heat input 2 for heaters of total rated heat input 60kW or more 540 cm plus 4 5 cm per kilowatt in excess of 60 kW total rated input b High Level outlet 1 for heaters of total rated heat input less than 60kW 4 5cm per kilowatt of rated heat input 2 for heaters of total rated heat input 60kW or more 270 cm plus 2 25 cm per kilowattin excess of 60kW total rated i
16. 412 2 0 440 66 o a 7 ___ __ NV120 D 2632 120 0 75 45 71 00 3 1215 284 2x150 NA 3635 NV140 44893 1400 9892 9255 3 6418 N 2x0550 67 260 H Note D data refers to Powrmatic supplied centrifugal silencer duct section 3 Table 3 1 Injector Sizes amp Burner Pressures Natural Gas Group G20 Net CV Hi 34 02MJ m Inlet HighFire _ LowFire Pressure INJECTORS Burner Burner e nem 7 4 194 50 127 231 40 123 Hen um emper 6 1941 50 19 345 40 194 5 __ 6 226 580 95 416 41 244 8 1941 50 127 460 40 256 Nvso 10 194 500 132 5 74 40 301 Nveo __ 8 254 750 95 690 27 377 6 35 1500 91 1008 35 619 120 8 35 150 91 1337 34 798 NV140 10 35 1500 84 15 76 4 0 10 47 Table 3 2 Injector Sizes amp Burner Pressures Propane G31 Net CV Hi 88 00MJ m inlet HighFie Pressure INJECTORS Burner Burner nu a 090 90 280 om 100 927 4 125 125 310 99 9047 Inlet Pressure 37mbar 6 125 125 270 133 100 075 Nvas 6 136 136 205 161 92 095 8 125 125 285 178 100 099 8 155 15 270 267 100 146 Nvoo 6 210 210 263 390
17. ces 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 outlets 3 7 Electrical Supply Wiring external to the air heater must be installed in accordance with the Regulations for Electrical Installations and any local regulations which apply All standard heaters are supplied by 230V 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 NV centrifugal fan silencer units can also be supplied for 400V 3N 50Hz 4 Installation of Air Heater s 4 1 General 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 1s located particularly where special risks are involved such as areas where petrol vehicles are housed whe
18. e 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 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 offtake 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 4 3 3 3 Internal Combustion Air Systems 1 Complete the run of flue sections from the terminal spigot to the flue outlet socket of the heater generally as described in 4 3 3 and 4 3 3 2 ensuring that the internal silicon sealing rings are in place 2 It is recommended that both air inlets are utilised and that both are fitted with the mesh inlet plates supplied In addition a 90 bend should be fitted to the rear inlet the inlet opening of the bend facing to the side of the heater i e away from the main air fan 4 4 Gas Connection Solid pipework must be fitted to the internal gas control and exit through the heater casing and then be fitted with a servicing valve and union to facilitate servicing The gas supply to the air heater must be completed in solid pipe work and be adequately suppor
19. eater 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 3 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 3 4 Flue System NV units 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 the flue system that is provided by Powrmatic Ltd Several configurations of flue and combustion air ducts are available See Page 7 amp 8 Figs la to 2b 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 3 5 Combustion Air Supply Air inlet grilles shall be provided at low level when combustion air is taken from within the space being heated and the building has a design air change rate less than 0 5 h and NV units are installed in heated spaces having a volume less than 4 7 m kW of total rated heat input 1 for heaters of heat input less than 60 kW the total minimum free area shall not be less than
20. eck burners for flame Wait at least 5 mins to see if fault self clears Confirm call for heat Check F1 3 15A fuse Check F2 3 15A fuse fuses ok If electricity supply is okay and combustion fan APS operate normally and no false flame is present but fault persists then replace control board If heater still will not start replace pcb 10 Short List of Parts Only originally specified parts may be fitted as service replacements and all items are available from the Powrmatic Ltd Spares Department Please refer to Powrmatic Ltd for any parts not shown in the listing ITEM MFC Honeywell VR4605AB1027 Honeywell VR425AB1007 Ignition Electrode Ignition Electrode Rectification Electrode Burner Bray P51 AB 19001 Burner Bray P51 AB 19002 Thermostat Limit Imit LS1 90 110 C Thermostat High temperature TOD60T13 60 C 9g Main PCB Hi Lo Governor Head Honeywell V4336A Modulating Governor Head Honeywell V7335A Modulating Driver Honeywell QM100A1009 Exhaust Fan Sifan WFFB 0223 006 Exhaust Fan Torin 077446 DSA424 215 Exhaust Fan Torin 077445 DSF180 042 Dungs Pressure Switch LGW3 A2 Contactor Danfoss CI 4 5 10 16 USAGE 10 90 120 140 10 75 90 140 10 140 10 75 90 140 10 140 HL 10 140 MOD 10 140 MOD 10 50 60 75 90 140 All 90 140 All C PART 145035204
21. ed person After any servicing work has been complete or any component replaced the air heater s must be fully commissioned and tested for soundness as described in Section 6 7 2 Main Burner Assembly Removal 1 Ensure that the gas service valve is turned OFF and then unscrew the union nut situated immediately down stream of it 2 Disconnect the spark and rectification leads from the electrodes and remove the electrical plug connections from the top of the gas control valve assembly 3 If required remove the manifold by removing the four screws securing it to the burner assembly 4 Remove the two screws that secure the top of the burner assembly to the bulkhead and lift out burner assembly 5 Using a stiff brush not a wire brush brush the burners to dislodge accumulated deposits Inspect the burners both internally and externally to ensure that they are clean Examine the injectors and if damaged or deteriorated replace with new ones of the correct size and marking If deemed necessary clean the injectors Do not broach out with wire 6 Reassemble the injectors manifold and burners in reverse order to that above 7 3 Ignition and Rectification Electrodes 1 Inspect the electrodes making sure that they are in a sound and clean condition In particular check that the ignition electrode is clean and undamaged Check that the spark gap is 2 5mm and that the rectification probe is 10 12mm forward of the burner Fig 8 Ignition Elec
22. er 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 pressures proceed as follows after levering off the plastic cover from the Hi Lo regulator Note High fire setting must be adjusted first after which the low fire setting can be set Any adjustment of the high fire setting alters the minimum setting If it is only necessary to adjust the low fire pressure setting proceed from step 11 i With the controls set to high fire use a 6mm hexagon wrench or 10mm screwdriver to turn adjustment screw for high fire pressure clockwise to increase and counter clockwise to decrease until the required pressure is obtained Turn the burner On and OFF several times to check the pressure setting and then turn off 11 Disconnect electrical connection of high low regulator and turn burners back on and wait until the burner pressure has stabalised Use a 3 5mm screwdriver to turn adjustment screw for low fire pressure clockwise to increase and counter clockwise to decrease until the required pressure is obtained Fig 6 High Low Regulator Adjustment screw for maximum pressure Honeywell T setting VR425AB1007 point Adjustment screw for minimum pressure setting Figure 5 Governor
23. gots on the heater 7 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 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 4 3 3 2 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 similar Fit a condensate drain lenth 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 Fig la Exhaust only system horizontal Combustion air entry fitted with inlet grille Adjustable Flue length outlet 2 Combus
24. n outlet sound attenuators must be capable of withstanding 100 C air temperature without any deterioration 5 3 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 are all positions to be avoided for siting the thermostat The thermostat should be mounted about 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 the accompanying wiring diagram 6 Commissioning amp Testing 6 1 Electrical Installation Checks to ensure electrical safety must be carried out by a qualified person Figure 3 General Controls Layout Burner Assembly Limit Thermostat Bracket Rectification Electrode Ignition Electrode 6 2 Gas Installation The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of IGE UP 1 Edition 2 or IGE UP 2A as appropriate 6 3 Air Distribution System The system should be checked to ensure that the installation work has been carried out in accordance with the design requirements Particular at
25. na level non combustible surface The surface must not extend past the front edge of NV F heaters The method of installation must be capable of adequately supporting the weight of the unit See Table 2 Page 3 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 Threaded drop rods must have lock nuts fitted that are tightened down onto the 10mm fixings in the heater If reducing noise levels is important the heater should be insulated from the structure by installing it on suitable anti vibration mountings In all such cases and when the heater is suspended it is essential that all gas duct and electrical connections to the heater are made with flexible connections to maintain continuity of connection 4 3 Flue Combustion Air Duct System models are supplied as standard with a top flue outlet and the flue outlet and combustion air sockets are loose inside the controls section 4 3 1 1 Conversion to Rear Flue Outlet Remove the two blanking plates from the flue combustion air openings at the rear of the unit 2 Remove the four screws from the exhaust fan oulet flange 3 Remove the two screws at the left hand side of the fan mounting plate that secure it to the exhaust header 4 Remove fan assembly by pulling forwards and to the left to disengage the retaining lugs 5 Rotate the fan a
26. nput 3 6 Air Distribution System Where single NV F 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 Various outlet configurations are available as optional extras to modify the air throw pattern to suit particular site conditions For ducted units all delivery and return air ducts including air filters jointing and any insulation or lining must be constructed entirely of materials which will not contribute to a fire are of adequate strength and dimensionally stable for the maximum internal and external temperatures to which they are to be exposed during commissioning and normal operation Where inter joist spaces are used as duct routes they should be suitably lined with a fire resisting material A full and unobstructed return air path to the air heater s must be provided If the air heater s is 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 through which the ducting passes must be fire stopped Care must be taken to ensure that return air intakes are kept clear of sour
27. nts See Figures 1 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 may be used each set being equivalent to 0 5m of flue length The minimum flue length end of flue terminal to back or top of heater shall not be less than 1 0m for the NV10 50 and 1 3m for the NV60 140 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 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 4 3 3 Installation of Flue System Note A terminal guard as supplied by Powrmatic Ltd must be fitted to horizontal flue terminals 4 3 3 1 Horizontal System Rear Outlet Note If the outlet is required to the side of the unit 90 bends may be fitted directly onto the inlet outlet spi
28. o gas valve Faulty PCB Yes Yes Faulty gas valve Ignition sparks Check replace rectification probe Faulty Yes Burners light Check gas pressures Replace gas valve Yes Burners remain e No 3 ignition attempts then goes to lock out probe lead alight Faulty PCB Yes 230V at main Check connections Check contactor Main fan runs No fan motor No Reset overload Faulty PCB Yes Yes Replace motor or fan motor assembly Heater working correctly Digital Powrmatic Control Board Part number 427301 Issue 1 20 01 09 Additional Diagnostic Aid The PCB has two LEDs A large LED labelled LOCKOUT next to the RESET Switch and a small DIAGNOSTIC LED close to CON11 Action Final Action Lockout LED OFF Control is in APS fault during safety shutdown Diagnostic LED start up Flashing Both LED s OFF but burners should be lit Control is in standby F1 Blown F2 Blown False flame detected No heat demand Limit stat tripped Reset Limit stat confirm ok Call for heat ok limit stat ok Mains voltage too Mains voltage is between low high Measure mains voltage 195 and 253V Check operation of combustion fan and APS Ch
29. ompanying these instructions NV D models supplied with a centrifugal fan silencer duct section require wiring to be completed between the heater and fan Refer to supplied wiring diagram NV D models supplied less fan must be electrically interlocked to the air movement system so that this is started in the same manner as the air heater fan would be viz A connection from the heater terminal marked Live Main Fan must be made to one side of the fan motor contactor coil the other side of the coil being connected to Neutral The fan motor electrical supply must not be taken direct from the internal wiring of the NV heater 5 Air Distribution System 5 1 General NV D models are designed for use with duct work to more precisely define the point of air delivery and or provide ducted return air or ducted fresh air inlet All ducting must be independently supported of the air heater Joints and seams of supply ducts and fittings must be securely fastened and made airtight If required the ductwork should be insulated to reduce heat loss 5 2 Noise Reduction Ducting should be connected to the heater spigots via an airtight flexible coupling of non combustible material Before fitting the coupling it must be ensured that a minimum clearance of approximately 15mm will be maintained between the ends of the ducting and the heater spigots Sound attenuators may be fitted inlet and outlet ducts to reduce airborne fan noise Materials used i
30. onal control 2 Set external controls so as to turn on the main burner Compare the measured burner gas pressure to that stated on the data plate If necessary adjust the burner gas pressure by turning the regulator screw anticlockwise to decrease the pressure or clockwise to increase the pressure Figure 4 Governor adjustment screw under cover cap 3 In addition it is advisable to check the gas rate using the gas meter dial pointer Ensure that no other appliances supplied through the meter are in operation If required after checking or setting the burner pressures the CO content in the flue gases be checked by sampling in the first section of flue fitted to the flue outlet of the unit Nominal CO values are given for guidance in the Table at the bottom of the page 5 Turn off the main burner as in 6 5 1 and disconnect the pressure gauge and replace the sealing screw Turn on the main burner as above and test for gas soundness around pressure test joint using a leak detection fluid e g soap solution 6 6 1 2 High Lo Regulator 1 Set external controls to ensure the main burner is off Remove the side access panel Connect a pressure gauge to the burner pressure test point on the multifunctional control 2 Set external controls to turn on the main burner and maintain high fire Compare the measured burner gas pressure to that stated on the data plate In addition it is advisable to check the gas rate using the gas met
31. ound pressure test joint using a leak detection fluid Replace access panel 6 6 2 Air Heater Controls 1 Close the gas service tap and ensure that the gas valve 1s heard to close within 1 second and that the lockout light is illuminated Note that the heater may attempt one reignition 11 before going to lockout Open the gas service tap and reset the unit from lockout 2 Check that the room thermostat and all automatic controls are operating satisfactorily 6 7 Handing over the Air Heater Hand these instructions to the user or purchaser for retention and instruct in the efficient and safe operation of the air heater and associated controls Adjust the automatic controls to those values required by the User Finally advise the user or purchaser that for continued efficient and safe operation of the air heater it is important that servicing is carried out annually In the event that the premises are not yet occupied turn off the gas and electricity supplies and leave instructional literature adjacent to gas meter 7 Servicing WARNING Always switch off and disconnect electricity supply and close the gas service valve before carrying out any servicing work or replacement of failed components NOTE If a suspended air heater is to be serviced do not lean ladders against the heater Ensure that an access tower or equivalent is used 7 1 General Full maintenance should be undertaken not less than once per year by a qualifi
32. re cellulose spraying is carried out in wood working departments etc NV C units are supplied with the centrifugal fan silencer section seperate from the heater which must be fitted at the rear of the NV heater 1 e the fan is blowing across the heat exchanger The following minimum clearances must be observed for installation and servicing RHS Clearance looking at front of heater 1 0m LHS Clearance looking at front of heater 0 2m Top of the heater to ceiling 0 2m Rear of heater to nearest wall 0 6m Depending on flue system used For multi air heater installations the following minimum distances between units must be observed Between units side to side 3 0m Between units back to back 3 0m Recommended mounting heights floor level to the underside of the unit are NVIOF 30F 2 5m 3m NV40F 150 3m 5m NV D Models Mounting heights not applicable All models must not be installed at a height of less than 2 5m to the base of the unit 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 When NV modular components are used in conjunction with the heater each component must be individually supported 4 2 Fitting the Air Heater The air heater may be installed either a suspended from suitable vertical drop rods chains or straps b on specifically designed cantilever brackets from a non combustible wall c o
33. s 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 amp Use Amendment Regulations It is law that all gas appliances are installed adjusted and 1f 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 Section Tables Figure Installation amp Servicing Instructions CONTENTS Title Introduction Technical Data General Requirements Installation Air Distribution System Commissioning amp Testing Servicing Connections to External Controls Fault Finding Flow Chart Short List of Parts Title Dimensions Specifications Injector Sizes amp Burner Pressures Natural Gas Group H G20 Injector Sizes amp Burner Pressures Propane G31 Electrical Loadings 1ph Title Exhaust only system horizontal Exhaust only system vertical
34. ssembly 90 clockwise Remove the fixing plate from the top of the fan box and reposition on the left hand side The screws from the left hand side are refitted at the top to close off the open holes Ensure that the gasket around the inlet to the fan is not damaged 1f necessary replace or make good with silicon sealant 6 Engage the locating lugs on the right hand side of the fan box into the slots on the collector box push fan against collector box and secure with the two screws at the left hand side 4 3 1 2 Fitting Flue Combustion Air Sockets 1 Apply a bead of silicon sealant around the face of the flange on the exhaust fan outlet tube that can be seen from the outside of the heater Place the flue socket on the outside of the heater to mate with this flange and clamp the two flanges together on either side of the heater panel using the screws provided Ensure that the silicon sealant has sealed between the two flanges 2 Apply a bead of silicon sealant around the face of the flange of the combustion air socket on the same side as the socket Passing the socket through the panel from the inside position the flange up against the panel Secure from the outside with the screws provided 3 If ducted combustion air is not required see Section 3 5 fit the mesh inlet plate behind the unused combustion air inlet hole 4 Apply silicon sealant and refit blanking plates as required to seal unused panel holes 4 3 2 General Requireme
35. st either the high fire or low fire pressures proceed as follows after removing the plastic cover from the Modulating regulator Note High fire setting must be adjusted first after which the low fire setting can be set Any adjustment of the high fire setting alters the minimum setting If it is only necessary to adjust the low fire pressure setting proceed from step 4 ii Fig 7 Modulating Regulator Shaft eee Adjustment nut 7mm for minimum pressure setting Adjustment nut 9mm for maximum pressure setting O ring 6 3mm AMP terminals 1 With the controls set to high fire turn adjustment screw for high fire pressure clockwise to increase and counter clockwise to decrease until the required pressure is obtained Turn the burner On and OFF several times to check the pressure setting and then turn off ii Disconnect electrical connection of modulating regulator and turn burners back on and wait until the burner pressure has stabalised Turn adjustment screw for low fire pressure clockwise to increase and counter clockwise to decrease until the required pressure is obtained Reconnect modulating regulator and check high fire pressure iv Repeat from step 1 if necessary v Replace cover cap 5 Turn off the main burner as in 6 5 1 disconnect the pressure gauge and replace the sealing screw Turn on the main burner as in 6 5 1 and test for gas soundness ar
36. ted 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 4 5 Electrical Connections units with the exception of NV D units supplied with a centrifugal fan silencer duct section are fully prewired and only require final connections for the incoming mains supply and completion of the control circuit 230V via a room thermostat time clock etc and the remote low level lockout reset Warning Lockout reset is by a switched Neutral to the controls in the heater units must be earthed The 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 See Table 4 Page 4 to ascertain the electrical loading of the unit s 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 external controls must be of an approved type See the wiring diagram acc
37. ted to the heater from an uncontaminated source preferably from outside the building The option of taking combustion air from the space is not permitted Where only airborne particles are present it may suffice to fit filters on the main air inlet duct of the heater and advice may be obtained from Powrmatic Ltd c Particular care should be taken to ensure chlorine vapours from Freon degreaser compounds etc are not induced into the combustion air stream as severe heat exchanger damage will result d In areas subjected to significant negative pressures due to extract systems 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 NV units are designed to operate within an ambient temperature range of 10 to 25 C 3 3 Gas Supply 3 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 3 3 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 3 3 3 Installation Pipes Installation pipes should be fitted in accordance with IGE UP 2 Pipework from the meter to the air h
38. tention should be given to the correct arrangement of delivery ducts and registers return air ducts and grills and general adequacy of return air paths For NV D units ensure that the ductwork 1s balanced so that the specified motor running currents are achieved 6 4 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 f Ifa Eurotrol or Powrtrol is being used ensure that the Summer Winter switch is in the Winter position g Check that the overheat reset button has not operated 6 5 Lighting the Air Heater NOTES 1 On initial lighting of the heater s it may take some time to purge the internal pipework of air IMPORTANT The internal pipework 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 e g soap solution Exhaust Fan Local Lockout Indicator and Reset Printed Circuit Board Pressure Switch Gas Valve 6 5 1 Models 1 Switch on the electrical supply at the isolator and the ignition sequence will commence After a delay of approximately 45
39. the limit thermostat Remove the securing nut and remove thermostat from the front panel 3 Fit replacement thermostat in reverse order 7 6 5 High Temperature Thermostat 1 Note their positions and then remove the electrical connections from the high temperature thermostat Remove the two securing screws and remove thermostat from the bulk head 2 Fit replacement thermostat in reverse order 7 6 5 Exhaust Fan 1 Remove the four screws securing the flue outlet socket 2 Disconnect the fan electrical connections from the terminals on the pcb 3 Remove the two screws at the left hand side of the fan mounting plate that secure it to the exhaust header 4 Remove fan assembly by pulling forwards and to the left to disengage the retaining lugs 5 If needed transfer the fan mounting box to the replacement fan 6 Fit replacement exhaust fan using new gaskets and silicon sealant as necessary and reassemble in reverse order 7 6 6 Air Pressure Switch 1 Disconnect electrical connections 2 Pull off the sensing tube from the air pressure switch 3 Note the setting of the old pressure switch 4 Remove the screws fixing the air pressure switch and remove switch 4 Fit replacement in reverse order refitting the sensing tube to the negative or L tapping on the pressure switch Adjust setting to that of the old pressure switch 7 6 7 Printed Circuit Board pcb 1 Disconnect all electrical connections 2 At each of the
40. tion air entry S fitted with inlet grille and inlet bend not shown Terminal Lengths LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 12m maximum Fig 15 Exhaust only system vertical Terminal Flashing 12m maximum Lengths NN Combustion air entry fitted with inlet grille Adjustable length Condensate drain length Flue Pd socket Combustion air entry fitted with inlet grille and inlet bend not shown Fig 2a Individual system horizontal Single to twin Terminal Flue socket adaptor Lengths jr 2 all Combustion air duct Adjustable length Combustion air socket 6m maximum Fig 2b Individual system vertical Z Terminal Single to twin adaptor 6m maximum Lengths Adjustable bw lengths Condensate drain f length Combustion air Flue socket socket p les Notes for all systems 1 Finaloverall 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 NV heaters are used in clean environments it is permissibl
41. tions in the design and construction of buildings Part 2 1985 Code of Practice for Shops Part3 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 NV10 to NV50 inclusive and installed so as to take their combustion air from within the building must be installed in accordance with the relevant recommendations ofthe 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 For NV D units of 10 50 size reference should also be made to BS 5864 Code of Practice for installation of gas fired ducted air heaters of rated input not exceeding 60kW 3 2 Location The location chosen for the air heater must permit provision of a satisfactory flue system and adequate air supply adequate space for servicing and air circulation around the air heater 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 In such cases installation may only proceed if the air to be heated is duc
42. trode Spark Gap E 7 4 Heat Exchanger Whilst the main burner assembly is removed from the unit check that the primary sections that the burners fire into are clean 7 5 Main Fan Assembly 7 5 1 NV F Models 1 Inspect the fan blades to see that they are not damaged and that there is no excessive build up of deposits that could give rise to an imbalance Should it be necessary to remove the assembly for cleaning proceed as follows 2 Slacken the cable gland on the heater casing through which the fan electrical cable passes 3 Disconnect the fan leads from the electrical terminals on the 4 Withdraw cable through entry grommet 5 Remove the fan and motor assembly complete by removing the four hexagon headed bolts that secure the fan to the rear panel 6 Reassemble in reverse order 7 5 2 Centrifugal Fan Silencer Section 1 Remove section side panel s and inspect the fan blades to see that they are not damaged and that there is no build up of excessive deposits that could give rise to an imbalance Should it be necessary to remove the assembly for cleaning proceed as follows 2 Slacken the cable gland on the casing through which the fan electrical cable passes 3 Disconnect the fan leads from the electrical terminals in the contactor enclosure 4 Withdraw cable through entry grommet 5 Remove the complete fan assembly by removing the fixings securing the fan to the base rails 6 Reassemble in reverse order
43. x Lockout 7 amp Heat Hi In 8 Heat Hi In 8 HeatHiOut 9 Heat Hi Out 9 Heat Lo In 10 Heat Lo In 10 LL Heat Lo Out 11 Heat Lo Out 11 Fan In 12 N Fan In 12 N Fan Out 13 Fan Out 13 L Out 14 L Out 14 N z 15 N z 15 E E 16 L 8 7 L 817 ON OFF NV Hi Lo NV Note The NV Heater PERROS 200 may be fed femeie serasi e COM 2 by separate electrical ni IN 2 3 y Separate Perd i Ni supplies providing both 5 supplies are the same MEE i L RESET 6 phase Lockout 7 2 Heat Hi In 8 HeatHiOu Heat Lo In 10 LL LIVE _ 4 Heat Lo Out 11 Fan In 12 N NEUTRAL Fan Out 13 2 EARTH _ A e N z 15 _ E 2 zdz 5 23 EEEE _ 2 9 lt l z 243 NV HEATER Modulating Modulating NV 13 LIVE LIVE Indicator 230V NV HEATER POWRTROL RR Le Push Button Reset I o R S N NV HEATER TIME SWITCH 14 LIVE NEUTRAL EARTH NV HEATER Lockout Indicator 230V Button Reset RIS b N E Note The NV Heater and Powrtrol or time clock may be fed by separate electrical supplies providing both supplies are the same phase
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