NV Installation Manual Issue 4.0 October 2009 With
Contents
1. Alternative flue positions 700 i eee H 120 e 455 8 LL 65 M Front Side NV60 D SHOWN Alternative 700 J flue positions Front Size Alternative flue positions NV140 F SHOWN Top TE AG Dimensions pwn J L E 192 502 120 262 5 ELI NV25 1000 506 176 um 172 5 142 236 5 E is sro 738 ete zes ono pe EE M 202 130 120 870 2345 870 244 5 1948 2014 88 a Table 2 Specifications AIR FAN NOISE e e pes om ie p Fe rae ze e or 35 wes 2 3932 350 251 100 10 E tee 40 wa m _ 685 114 e pes wo nen ee a ro Es we op NV120 D 12632 120 0 7545 71 00 3 1215 L2x0550 ___67 260 25 2x15 3635 140 L 148 93 1400 98 92 9255 36418 2x0550 67 260 B Note D data refers to Pow2. Yes Gas amp Electrical 1 No Turn supplies on supplies present at heater Check fuses connections M Check connections and 3 15A fuse replace fuse if necessary Yes ee ee on No Check Fuse on Brahma control box If fuse is okay replace control box Yes 230V Between N amp 1 on the terminal strip No Check limit thermostats reset manual thermostat Check connections Yes Check air pressure switch N C for 230V If not present reset set point Exhaust fan runs No Check lock out reset Okay Check for 230V between terminals pay Brahma Control 5 amp 6 on the terminal strip Yes Yes Faulty exhaust fan Ves Check for 230V at and or capacitor the exhaust fan 230V to air pressure No 1 Check pressure sensing tube Adjust pressure No Switch N O switch set point Change pressure switch Check connections Yes Ign
3. fitted with inlet grille inlet bend not shown LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 12m maximum Fig Ib Exhaust only system vertical Terminal _ Flashing _ 12m maximum Lengths bmc Adjustable Combustion air entry length fitted with inlet grille Flue Pd socket Combustion air entry fitted with inlet grille and inlet bend not shown Condensate drain length Fig 2a Individual system horizontal Single to twin Terminal Flue socket adaptor Lengths Combustion air duct Adjustable length pr Combustion air socket 6m maximum Fig 2b Individual system vertical A Terminal P Flashing Single to twin adaptor 6m maximum Lengihs TT Adjustable lengths Condensate drain length pipa uq L ___ Flue socket 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
4. 4j powrmatic The NV Range Users Installation and Servicing Instructions TESTED STAGE 1 E mechanical construction assembly nd electrical sequence che ck STAGE 2 Full functional test in accordance with Quality System Procedures Heater 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 4 0 December 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 a
5. All Powrmatic heaters use gas and electricity to power them they may also contain moving parts such as pulley belts It would be hazardous to tamper with or attempt to service unless you are a competent person in the field of Gas and Electrical work If you have any safety questions reference the servicing and installation of any of our heaters please do not hesitate to contact our head office for expert advice Your safety is paramount to us Gas Safety Installation amp Use Amendment Regulations It is law that all gas appliances are installed adjusted and if necessary converted by qualified persons in accordance with the current issue of the above regulations Failure to install appliances correctly can lead to prosecution It is in your own interests and that of safety to ensure that the law is complied with An approved class of person listed on the gas register Section Se YN Tables Figure Installation amp Servicing Instructions CO NT ENT 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 Exha
6. ii Where NV 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 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 1 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 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 slac
7. 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 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 w
8. 10 140 142423003 Burner Bray P51 AB 19001 10 75 142400240 Burner Bray P51 AB 19002 90 140 142400241 Thermostat Limit Imit LS1 90 110 C P All 142403609 Thermostat High temperature Klixon TOD60T13 60 C 143000310 Control Brahma DMN 32 All 145030844 Hi Lo Governor Head Honeywell V4336A 10 140 HL 142466402 Modulating Governor Head Honeywell V7335A E 10 140 MOD 142466403 Modulating Driver Honeywell QM100A1009 10 140 MOD 142400305 Exhaust Fan Sifan WFFB 0223 006 10 50 140210499 Exhaust Fan Torin 077446 DSA424 215 60 75 140201505 Exhaust Fan Torin 077445 DSF180 042 90 140 140201506 Dungs Pressure Switch LGW3 A2 146522174 Contactor Danfoss 4 5 10 90 140 All C 143016131 16 BSI Registered Firm FM 414 Ind amp Comm Air Heaters ESI Air Moving Equipment Flues amp Chimneys Natural Smoke amp Heat Ventilators Powered Supply amp Extract Fans amp Systems ISO 9001 HEATING DIVISION Hort Bridge Somerset TA19 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
9. 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 Su pply 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 The inlet gas pressure under running conditions must not be less than 17 5mb 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 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 3 3 4 Boosted Supplies Where it is necessary to employ a gas
10. 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 Figure 3 General Controls Layout Burner Assembly Rectification Electrode Ignition Electrode 6 Commissioning amp Testing 6 1 Electrical Installation Checks to ensure electrical safety must be carried out by a qualified person 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 attention should be given to the correct arrangement of delivery ducts and registers return air ducts and grills and g
11. 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 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 cm per kilowatt in excess of 60 kW rated heat input Where the air heater s are to be installed in a pla
12. 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 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 Ensure that the Summer Winter switch is in the Winter position g Check that the overheat reset button has not operated 2 Lighting the A
13. H units are for use in air 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 10mm Suspension Points Alternative flue positions 700 s 120 n H um F A 455 Front Side Top NV20 D WITH CENTRIFUGAL FAN SILENCER SECTION SHOWN
14. 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 5 NV D Models Mounting heights not applicable 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 ona 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
15. ala Note ph Data is supplied seperately with units ordered to this 130 256 135 84 specification 7 NV50 3 vto s Nv90 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 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 precautions in the design and construction of buildings Part 2 1985 Code of Practice for Shops 3 1983 Code of Practice for Office Buildings BS 6230 1991 Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial Space Heating Those appliances having a gross input rating not exceeding 60kW viz NV10 to NV50 inclu
16. an 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 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 rings if necessary 7 6 2 Burners 1 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 Di
17. damaged if 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 Requirements See Figures 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 i
18. el savings LIVE dis iac N X l EARTH E EARTH o 11 3 2 H 2 I 5 9 8 Y 9 H E 4 Ej 14 gt gt SETHE Remote Senso Remote Senso 7 7 7 7 optional ca 3 nmm 1 1 Po EE To are eee 2 PME hs 2 i ove 2 3 S IN 5 o t0v 5 K 0 10 5 4 mo 6 gt 1 Lockout 7 o RESET 6 a i Heat Hi In J Lockout 7 o L HeatHiOu 9 Heat Hi In 8 oa ee Heat Lo In 10 LL Heat Hi Out 9 D L hetloot 11 1 Heat Lo 10 Ws Fan In 12 N Mao S mo Q Fan In 12 N 1 L Out 14 Fan Out 13 45 i L Out 14 E E 16 N z 15 L 9 17 16 66 L wv On Off NV Hi Lo NV 1 Remote Senso 2 optional 3 r2 1 Ba Bs ui i 6 lt 7 o 1 8 J 2 10 12 lt 13 2 14 LIVE 15 NEUTRAL E 16 EARTH Pat E Note The NV Heater and MC200 be fed by separate NV HEATER Modulating electrical supplies providing both supplies the sa
19. eneral adequacy of return air paths For NV D units ensure that the ductwork is 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 Exhaust Fan Control Box Pressure Switch Gas Valve 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 6 5 1 All Models 1 Switch on the electrical supply at the isolator and the ignition sequence will commence After a delay of approximately 45 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 t
20. ers 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 Electrode Spark Gap 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 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 peb 4 Withdraw cable through entry grommet 5 Remove the fan and motor assembly complete by removing the four hexagon headed bolts that secure the f
21. ir Heater NOTE On initial lighting of the heater s it may take some time to purge the internal pipework of air If it is not possible to light the heater after several attempts contact the local service company 1 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 1 2 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 4 1 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 automatical
22. ithin 900mm of the outlets 3 7 Electrical Supply Wiring external to the air heater must be installed in accordance with the L E E 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 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 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 i e the fan is blowing across the heat exchanger
23. ition sparks No Check replace ignition probe Faulty Brahma control box Yes Check for 230V between terminals Gas valve opens No 3 84 on the terminal strip No Faulty Brahma Control Box Yes Yes Faulty Gas Valve Check gas pressures Burners light No Replace gas valve Yes Burners remain alight pm Check rectification probe lead 9 5 ignition attempts then goes to lock out Faulty Brahma Control Box Yes 230 on terminals 8 amp 9 on Check for 230V on terminal 15 Main fan runs No the terminal strip No of the terminal strip Yes Yes Faulty Brahma Control Box No working Faulty fan timer module Yes Check voltage at the N Check connections on the coil of the fan relay 9 terminal strip Yes Check for 230V at the main fan motor No Ghee the fan relay Yes Replace motor or fan motor assembly 15 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 USAGE PART MFC Honeywell VR4605AB1027 e 10 90 145035204 Honeywell VR425AB1007 120 140 141378715 Ignition Electrode 10 75 142423002 Ignition Electrode 90 140 142423004 Rectification Electrode an
24. k 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 ofthe 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 accompanying 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 supp
25. licon 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 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 Fig la Exhaust only system horizontal Combustion air entry fitted with inlet grille Adjustable Lengths Flue length outlet 2 Combustion air entry
26. lied wiring diagram NV D models supplied less fan must be electrically interlocked to the air movement system so that this 1 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 joints between NV ancillary components must be securely fastened and made airtight using appropriate sealants or sealing strips 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 in inlet and outlet ducts to reduce airborne fan noise Materials used in outlet sound attenuators must be capable of withstanding 100 C air temperature without any
27. 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 Control Box 1 Unplug all the electrical connections 2 Remove the four screws that secure the control box in place 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 fu
28. ly start between 0 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 4 2 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
29. me phase Modulating NV 13 LIVE NEUTRAL ON OFF NV EARTH Remote Senso optional mletej rM COM 1 IN 2 0 10V 0 10V Mod Out RESET Lockout Heat Hi In Heat Hi Out Heat Lo In Heat Lo Out Fan In Fan Out L Out N SUPPLY IN LIVE NEUTRAL jux rz LIVE c NEUTRAL 2 Q lt gt 2 1 2 3 4 6 4 8 5 10 11 12 a 14 15 16 17 EARTH Lockout Indicato 69 230V Push Button R e aet IR S N NEUTRAL EARTH NV HEATER ON OFF Lockout Indicato 230V ush Button o L 2 T E 1 gt 2 8 9 13 14 w 777 E 02 o E L N T E 1 gt 2 v 9 13 14 w Note The NV Heater Powrtrol or time clock be fed by separate electrical supplies providing both supplies are the same phase 9 Fault Finding Flow Chart
30. nt 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 plus 2 25 cm per kilowattin excess of 60kW total rated input 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
31. o lockout and the remote lockout light will be illuminated To restart the ignition sequence depress the reset button adjacent to the lockout light for about 1 2 seconds 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 is 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 is off Open the side access door 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 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 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 can 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 bo
32. rchaser that for continued efficient and safe operation ofthe 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 qualified 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 burn
33. rmatic 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 HighFie _ LowFire Pressure INJECTORS Burner Burner D NV10 NV15 NV20 NV25 niet pressure NV30 6 194 500 119 345 40 194 17 5mbar NV35 6 2 26 580 95 416 41 244 NV40 8 194 500 135 460 40 256 NV50 NV60 8 254 750 95 690 27 37 NV75 NV90 6 35 1500 10 08 NV120 8 35 1500 13 37 NV140 10 3 5 1500 8 4 15 76 4 0 10 47 Table 3 2 Injector Sizes amp Burner Pressures Propane G31 Net CV Hi 88 00MJ m iit High Fire Pressure INJECTORS Burner Burner ee 10 4 0 90 90 280 044 100 027 NV15 Inlet P NV20 4 1 25 125 310 089 99 047 NV25 aimar NV30 6 125 1235 270 133 100 075 NV35 6 136 136 205 161 92 095 NV40 8 1 25 125 285 178 100 099 50 NV60 8 1 55 155 270 267 100 146 NV75 NV90 6 210 210 263 390 98 239 120 8 210 210 270 5 17 100 309 140 10 2 10 210 26 1 6 09 9 5 4 04 4 Electrical Loadings 1ph IF Models Centrifugal Fan Sections 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 vo 00 034 026 1400 2
34. round 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 adjust 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 11 Fig 7 Modulating Regulator Shaft Adjustment nut 7mm for minimum pressure setting Cap Adjustment nut ik for maximum pressure setting 5 O ring 6 3mm AMP terminals d ore 1 With the controls set to high fire turn adjustment nut for high fire pressure clockwise to increase and counter clockwise to decrease
35. s 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 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 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 spigots on the heater 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 si
36. s obtained Turn the burner On and OFF several times to check the pressure setting and then turn off ii 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 screw under cover cap m SM pressure Honeywell C setting VR425AB1007 Adjustment screw for minimum pressure setting 2 Figure 5 Governor adjustment screw under cover cap Honeywell VR4605A B1027 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 3 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 1 High Fire CO2 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 iv Repeat from step i 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 a
37. sconnect 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 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 C NV 15 and 20 100 C NV 35 110 C 1 Remove the screws securing the thermostat phial mounting 12 plate to the inner bulkhead withdraw assembly and unclip the phial 2 Remove the electrical connections from 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
38. sive and installed so as to take their combustion air from within the building must be installed in accordance with the relevant recommendations of the following document BS 5440 Flues and Air Supply for gas appliances of rated input not exceeding 60kW 1st and 2nd family gases Part 2 Air Supply 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 8 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 ducted 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
39. 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 1 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 assembly 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
40. ttom 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 1 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 adjust either the high fire or low fire pressures proceed as follows after levering offthe 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 ii 1 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 i
41. 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 nut for low fire pressure clockwise to increase and counter clockwise to decrease until the required pressure is obtained iii Reconnect modulating 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 2 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 1 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 pu
42. ust only system vertical 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 D
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