AGCO AP Cumberland VariFlame VF-16-EPS User manual

VariFlame™Heater with EDGE®
Connect
Patent Pending
Models:
VF-16–EPS, VF-16–EPP, VF-16–EPG
VF-16–ENG, VF-16–ENS, VF-16–ENP
Owner’s Manual
PNEG-2092
Version 1.0
Date: 09-14-16
PNEG-2092

Use of this Equipment Information page will help you identify your equipment in the case that you need to
notify the company. For this reason, this information should be filled out and kept on record.
Equipment Information
Model Number:
Serial Number:
Date Purchased:
Dealer Name
and Phone Number:
All information, illustrations, photos, and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any
time without notice.
2Pneg-2092 VariFlame Heater with Edge Connect

Contents
Chapter 1 Safety Precautions ....................................................................................................................5
Safety Guidelines........................................................................................................................5
Cautionary Symbol Definitions......................................................................................................6
Safety Precautions ......................................................................................................................7
Safety Decals ...........................................................................................................................12
Safety Sign-off Sheet.................................................................................................................14
Chapter 2 Specifications .........................................................................................................................15
VariFlame vapor propane specifications ......................................................................................15
VariFlame natural gas specifications...........................................................................................16
Chapter 3 System Overview ....................................................................................................................17
User Interface ...........................................................................................................................18
Typical Controller Connections...................................................................................................21
Heater component functions ......................................................................................................22
Burner control module and sequence of operation .......................................................................24
Operation modes ......................................................................................................................26
Chapter 4 Installation ..............................................................................................................................29
Installing the air diverter.............................................................................................................29
Installing for recirculating operation (indoor) ................................................................................30
Pipe sizing guidelines ................................................................................................................32
Wiring Diagrams and Schematics ...............................................................................................36
Chapter 5 Controller Settings ..................................................................................................................41
The Main Screen.......................................................................................................................41
Turning OFF the heater..............................................................................................................42
Setting the parameters for the heater..........................................................................................42
Setting the parameters for a Variable Input Mode.........................................................................43
Setting the parameters for Standalone Mode...............................................................................46
Setting the parameters for Legacy Mode .....................................................................................47
Enabling a second probe ...........................................................................................................49
Testing the LED probes with blink mode ......................................................................................51
Checking the System Status ......................................................................................................52
Chapter 6 Startup and Operation .............................................................................................................53
Pre-startup inspections ..............................................................................................................53
Emergency heater shutdown......................................................................................................53
Normal heater shutdown............................................................................................................53
Starting the heater.....................................................................................................................54
Operating the burner .................................................................................................................54
Adjusting the heater output ........................................................................................................54
Chapter 7 Service and Maintenance ........................................................................................................57
Cleaning the heater ...................................................................................................................57
Guidelines for checking gas pressure .........................................................................................57
Checking the valve inlet pressure ...............................................................................................58
Checking the valve output pressure ............................................................................................58
Replacing the motor and fan wheel.............................................................................................59
Replacing the air proving switch .................................................................................................61
Replacing the Temperature High Limit Switch..............................................................................62
Replacing the Flame Probe........................................................................................................64
Replacing the Ignitor..................................................................................................................66
Replacing the control board .......................................................................................................67
Replacing the gas valve.............................................................................................................68
Chapter 8 Troubleshooting......................................................................................................................71
Troubleshooting ........................................................................................................................71
LED meanings ..........................................................................................................................74
Pneg-2092 VariFlame Heater with Edge Connect 3

Chapter 9 Parts List.................................................................................................................................75
VariFlame EDGE Controller Parts...............................................................................................75
Switch and Probe Parts .............................................................................................................76
Gas Parts .................................................................................................................................77
Motor and Blower Wheel Parts ...................................................................................................78
GSI Group, LLC Limited Warranty ...........................................................................................79
4Pneg-2092 VariFlame Heater with Edge Connect

1Safety Precautions
Topics Covered in this Chapter
▪ Safety Guidelines
▪ Cautionary Symbol Definitions
▪ Safety Precautions
▪ Safety Decals
▪ Safety Sign-off Sheet
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered by the
operator and other personnel when using this equipment. Save these safety guidelines for future
reference.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all
times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable regula-
tions, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be delivered
with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the
equipment.
ST-0001–3
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Chapter 1: Safety Precautions
Cautionary Symbol Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
Table 1-1 Description of the different cautionary symbols
Symbol Description
This symbol indicates an imminently hazardous situation which, if
not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to personal
injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005–2
6Pneg-2092 VariFlame Heater with Edge Connect

Chapter 1: Safety Precautions
Safety Precautions
Use Personal Protective Equipment
• Use appropriate personal protective equipment:
Eye
Protection
Respiratory
Protection
Foot
Protection
Hearing
Protection
Head
Protection
Fall
Protection
Hand
Protection
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004–1
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Chapter 1: Safety Precautions
Follow Safety Instructions
• Warning: If the information in the manual is not followed
exactly, a fire or explosion can result, causing property
damage, personal injury or loss of life.
• Carefully read all safety messages in this manual and safety
signs on your machine. Keep signs in good condition.
Replace missing or damaged safety signs. Be sure new
equipment components and repair parts include the current
safety signs. Replacement safety signs are available from
the manufacturer.
• Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
• Retain these instructions for future reference.
ST-0025–3
For Your Safety
• If you smell gas:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flames.
4. Immediately call your gas supplier.
• Do not store or use gasoline or any flammable vapors and
liquids in the vicinity of this or any other appliance.
ST-0064–1
General Hazard Warning
• Failure to comply with precautions and instructions provided
with this heater can result in death, serious bodily injury and
property loss or damage from hazards of fire, explosion,
burn, asphyxiation, carbon monoxide poisoning, and/or elec-
trical shock.
• If you need assistance or heater information such as an
instruction manual, labels, etc. contact the manufacturer.
ST-0065–1
8Pneg-2092 VariFlame Heater with Edge Connect

Chapter 1: Safety Precautions
Maintain Equipment and Work Area
• Do not attempt maintenance or repairs on the heater unless
you are competent to do so. Understand service procedures
before doing work.
• Use only genuine Cumberland/AP parts when maintaining
the heater. Use of other non-genuine parts is a misuse and
may lead to dangerous situations.
• Heater should be inspected before each use and at least
annually by a qualified service person.
• Be aware that the heater may operate under automatic con-
trol and may start without warning.
• Do not service the heater without first disconnecting and
locking-out power.
• Keep area clean and dry.
• Keep hands, feet, and clothing away from moving parts.
• Keep the heater in proper working condition. Replace worn
or broken parts immediately.
• Keep the heater clean. Do not allow debris to collect around
motor, blower wheel, burner or controls. Burner orifice and
hot surface igniter must be kept clean and free of carbon
build up.
• Be sure that all electrical enclosures and guards are closed
and locked before re-starting the heater.
• Igniter must be cool before wash-down. Heater must not be
operated for one hour following wash-down.
ST-0067–1
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Chapter 1: Safety Precautions
Install and Operate Gas-Fired Equipment Properly
• Gas-fired equipment should be installed by a qualified pipe
fitter and must conform with local codes.
• For Canada: The equipment shall be installed in accordance
with the Natural Gas and Propane Installation Code, CSA
B149.1, or the Propane Storage and Handling Code, CSA
B149.2, or applicable provincial regulations, which should be
carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
• For the United States: The equipment shall be installed in
accordance with the National Fuel Gas Code ANSI Z223.1/
NFPA 54.
• Check all connections for gas leaks.
• Do not operate heater with door open or panels.
• Do not move or handle heater while it is operating, hot, or
connected to power supply.
• Adequate ventilation is required. Combustion and ventilation
air must not be obstructed.
ST-0068–1
10 Pneg-2092 VariFlame Heater with Edge Connect

Chapter 1: Safety Precautions
Install and Operate Electrical Equipment Properly
• The electrical connections and grounding of the appliance
shall be in compliance with the National Electric Code ANSI/
NFPA 70 for the United States or the Canadian Electrical
Code for Canada, as well as all local and state codes.
• This appliance is equipped with a three prong (grounding)
plug for your protection against electrical shock and should
be plugged directly into a properly grounded three-prong
receptacle. Failure to use a properly grounded receptacle
can result in electric shock, personal injury or death.
• If permanently connected to power supply, make sure a cir-
cuit breaker or similar cutoff device is provided to permit dis-
connection of power for servicing.
• Electrical equipment must be installed by a qualified
electrician.
• Lock-out power source before making adjustments, cleaning,
or maintaining equipment.
ST-0069–1
Improper Use Warning
• The intended use of this appliance is the heating of agricul-
tural animal confinement buildings.
• Not for home or recreational vehicle use. Installation of this
heater in a home or recreational vehicle may result in a fire
or explosion, property damage, personal injury or loss of life.
• Heater is not recommended for heating human living
quarters.
• Keep solid combustibles, such as building materials, paper,
cardboard, feathers, straw and dust a safe distance away
from the heater as recommended by the instructions.
• Never use the heater in spaces which contain or may con-
tain volatile or airborne combustibles, or products such as
gasoline, solvents, paint thinner, dust particles, or unknown
chemicals. Failure to follow these instructions may result in
a fire or explosion, property damage, personal injury or loss
of life.
ST-0066–1
Pneg-2092 VariFlame Heater with Edge Connect 11

Chapter 1: Safety Precautions
Safety Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood
by all personnel involved in the installation, operation, service and maintenance of the equipment.
Location Decal No. Decal Description
Inside door
panel DC-2426
Warning Electrical Hazard
Instructions
Wiring Diagram
On heater frame DC-2427
Danger: Suffocation Hazard
Warning: Electrical, Fire, and
Heat Hazard
Notice
12 Pneg-2092 VariFlame Heater with Edge Connect

Chapter 1: Safety Precautions
Location Decal No. Decal Description
On Door DC-2429 Caution
On Door DC-2430 Warning: Hot Surface
To replace a damaged or missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois St.
Assumption, IL 62510
Tel: [phone]
Pneg-2092 VariFlame Heater with Edge Connect 13

Chapter 1: Safety Precautions
Safety Sign-off Sheet
Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
ST-0007
14 Pneg-2092 VariFlame Heater with Edge Connect

2Specifications
Topics Covered in this Chapter
▪ VariFlame vapor propane specifications
▪ VariFlame natural gas specifications
VariFlame vapor propane specifications
Maximum input 250,000 (BTUH)
Minimum input 50,000 (BTUH)
Ventilation air required to support combustion 1,050 (CFM)
Inlet gas supply pressure maximum 13.5 in. W.C.
Inlet gas supply pressure minimum 12.0 in. W.C.
Burner manifold pressure maximum 10.0 in. W.C.
Burner manifold pressure minimum 0.4 in. W.C.
Fuel consumption per hour maximum 11.58 lbs.
Fuel consumption per hour minimum 2.32 lbs.
Motor characteristics 1/3 H.P. 1100 RPM
Electrical supply (Volts/Hz/Phase) 115/60/1
Amp draw (Starting) 9.5
Amp draw (Continuous) 4.5
Dimensions (Inches) L x W x H 30.3 x 18.6 x 27.5
Net weight 98 lbs.
Shipping weight 112 lbs.
Minimum combustion distance
Top 1 ft. (0.3 m)
Sides 1 ft. (0.3 m)
Back 1 ft. (0.3 m)
Blower outlet 6 ft. (1.83 m)
Pneg-2092 VariFlame Heater with Edge Connect 15

Chapter 2: Specifications
VariFlame natural gas specifications
Maximum input 250,000 (BTUH)
Minimum input 50,000 (BTUH)
Ventilation air required to support combustion 1,050 (CFM)
Inlet gas supply pressure maximum 13.5 in. W.C.
Inlet gas supply pressure minimum 7.0 in. W.C.
Burner manifold pressure maximum 10.0 in. W.C.
Burner manifold pressure minimum 0.4 in. W.C.
Fuel consumption per hour maximum 238 cu. ft.
Fuel consumption per hour minimum 47.6 cu. ft.
Motor characteristics 1/3 H.P. 1100 RPM
Electrical supply (Volts/Hz/Phase) 115/60/1
Amp draw (Starting) 9.5
Amp draw (Continuous) 4.5
Dimensions (Inches) L x W x H 30.3 x 18.6 x 27.5
Net weight 98 lbs.
Shipping weight 112 lbs.
Minimum combustion distance
Top 1 ft. (0.3 m)
Sides 1 ft. (0.3 m)
Back 1 ft. (0.3 m)
Blower outlet 6 ft. (1.83 m)
16 Pneg-2092 VariFlame Heater with Edge Connect

3System Overview
Topics Covered in this Chapter
▪ User Interface
▪ Typical Controller Connections
▪ Heater component functions
▪ Burner control module and sequence of operation
▪ Operation modes
Pneg-2092 VariFlame Heater with Edge Connect 17

Chapter 3: System Overview
User Interface
Item Description
APress to go up in the menu or to increase a parameter value.
BPress to go down in the menu or to decrease a parameter value.
CEnter function in a menu or to edit a parameter.
D24Vdc supply state
E Lock mode activation state
F EDGE Automation network state
GEDGE Safety network state
HON/OFF toggle switch
I Menu screen
18 Pneg-2092 VariFlame Heater with Edge Connect

Chapter 3: System Overview
Figure 3-1 User Interface Flow Chart
Pneg-2092 VariFlame Heater with Edge Connect 19

Chapter 3: System Overview
Figure 3-2 User Interface Flow Chart
20 Pneg-2092 VariFlame Heater with Edge Connect