Clarke 900DV User manual

USER INSTRUCTIONS
ORIGINAL INSTRUCTIONS LS0618 - ISS 1
GAS HEATERS
MODEL NOS: 900DV,1600DV & 2100DV
PART NOS: 6920175, 6920191 & 6920196

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INTRODUCTION
Thank you for purchasing this CLARKE Gas Powered Heater.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
FUNCTION AND OPERATING PARAMETERS
This is a gas powered heater. It’s intended use is for drying and the warming of
commercial/industrial buildings where adequate ventilation is provided.
• It must be operated as prescribed in the operating manual.
• Is not intended to be used for domestic use or for the heating of
habitable areas.
• Is not intended to be used to reach and maintain a certain level of
human thermal comfort within an enclosed space in which the heater is
situated.
• Is not intended to be used in enclosed areas with restricted ventilation.
• Is not for use in areas with high levels of fluctuating drafts.
• Is not intended for warming animals or live stock.

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CARBON MONOXIDE
WE RECOMMEND THAT YOU USE A CARBON MONOXIDE
DETECTOR, AVAILABLE FROM YOUR CLARKE DEALER
WHAT ARE THE SIGNS
The 6 symptoms to look out for:
The following groups of people are more likely to be effected by Carbon
Monoxide.
1. Pregnant women,
2. Persons with a heart or lung condition, anaemia
3. People under the influence of alcohol,
4. Those living/working at high altitude
WHAT TO DO IF YOU SUSPECT CO POISONING
• Get fresh air immediately. Open doors and windows, switch off the
heater and leave the area.
• See your doctor immediately or go to hospital - let them know that you
suspect CO poisoning. They can do a blood or breath test to check.
• Do not use the heater until it has been serviced.
WARNING: LACK OF AIRFLOW CAN CAUSE CARBON MONOXIDE
POISONING.
WARNING: CARBON MONOXIDE POISONING CAN KILL.
• Headaches • Breathlessness
• Dizziness • Collapse
• Nausea • Loss of consciousness

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SAFETY INFORMATION
Read, and make sure you fully understand the following precautions and the
hazards associated with this type of heater.
• Use only liquid propane gas with this heater.
• Make sure that the Propane gas bottle, gas hose and electric cable, are
positioned behind the unit, away from the heat.
• Make sure that the gas hose and regulator connections are gastight
and the hose is not kinked.
• Do not use the heater where flammable vapours or if a high dust
content is present in the air.
• Only use with the voltage specified and make sure that the heater is
properly earthed.
• Use only in well ventilated areas. Provide ventilation of at least 3 square
feet of fresh air for every 100,000 BTU/hr of rating.
• Always allow the working clearances around the heater as stated on
page 8.
• Keep the heater as far as practical from propane tanks and do not point
the heater directly at any propane tank.
• Stand the heater on a stable, level surface whilst hot or operating. If the
heater overturns, a fire can occur.
• Keep children and animals away from heater at all times.
• Use heater in accordance with all fire regulations.
• Do not use heater for domestic heating in living or sleeping areas.
• Do not leave a heater plugged in without adult supervision if children or
animals are likely to be present.
• Do not move, handle, replenish the gas supply or service the heater
when it is hot, operating or plugged in.
• Do not attach the heater to any duct work, or impede air flow into or out
of the heater.
• Disconnect the heater from the power supply when not in use.
• Use ONLY the factory pre-set regulator supplied with the heater.
• If the heater works for long periods at maximum capacity, be aware
that it is possible for ice to form on the gas cylinder due to excessive
evaporation.
• Do not direct hot air towards the gas cylinder in order to de-ice.

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• Do not use in wet areas, basements or below ground level. Propane gas
is heavier than air and will sink to the lowest possible level.
• Make sure that the heater is correctly maintained in accordance with
this manual.
• This heater can be used by children aged from 8 years and above and
persons with reduced physical, sensory or mental capabilities or lack of
experience and knowledge if they have been given supervision or
instruction concerning use of the appliance in a safe way and
understand the hazards involved.
• Children shall not play with the heater. Cleaning and user maintenance
shall not be made by children without supervision.
• If the supply cable is damaged, it must be replaced by a special cable
or assembly available from the manufacturer or its service agent.
SAFETY SYMBOLS
The following safety symbols may be found on the product.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
General hazard
warning
Danger-Hot Surfaces.
Always read the
manual before use
.

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ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug or a suitably fused isolator switch.
The heater may also be connected to a 110V supply through a suitably
approved plug.
TO CHANGE THE VOLTAGE
1. Remove the two screws shown.
2. Rotate the cover so that the
voltage you want is at the top
(230V or 110V).
3. Replace the cover and screws.
4. Make sure that the plug is suitable
for the voltage selected and
replace it if necessary..
As the colours of the flexible cable of this appliance may not correspond with
the coloured markings identifying terminals in your plug proceed as follows:
• Connect GREEN & YELLOW cord to terminal marked with a letter “E” or
Earth symbol
• Connect BROWN cord to terminal marked with a letter “L”
• Connect BLUE cord to terminal marked with a letter “N”
If this appliance is fitted with a plug which is moulded onto the electric cable
(i.e. non-rewirable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the
correct replacement is used (as indicated by marking or colour code).
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.
WARNING: WARNING! THIS APPLIANCE MUST BE EARTHED
WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

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4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
5. The fuse in the plug must be replaced with one of the same rating (13
amps) and this replacement must be ASTA approved to BS1362.
We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD).
If in doubt, consult a qualified electrician. Do not attempt any electrical
repairs yourself
UNPACKING
When unpacking, examine the heater for possible shipping damage. Should
any damage be apparent, please notify your Clarke dealer immediately.
Your heater is fully assembled,only the electrical and gas supplies need
connecting. Retain any plastic cover caps (attached to the inlet connector
and hose/regulator assembly) for future storage.
PROPANE GAS SUPPLY
These heaters are designed for use with PROPANE GAS ONLY. Gas cylinders are
not supplied, but are readily available from builders merchants or gas suppliers
etc.
This range of portable, direct fired gas heaters are designed to BS 4096 for
industrial applications to give safe, efficient and reliable operation.
As with all mechanical equipment, optimum performance will only be
achieved if the correct operation and servicing procedures are followed.
WARNING: PROPANE GAS CYLINDERS MUST BE USED AND STORED IN
ACCORDANCE WITH THE HIGHLY FLAMMABLE LIQUIDS AND LIQUEFIED
PETROLEUM GASES REGULATIONS 1972

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GAS CONNECTION
Connect the free end of the gas hose to the gas inlet connection on the
heater and tighten to ensure there are no gas leaks. Before attaching the
regulator to the gas cylinder, ensure the mating parts are free from grease and
dirt and are undamaged.
Fit the regulator to the cylinder,
tightening the thread as tight as
possible with a propane spanner,
noting that the threads are LEFT
HANDED. To check for leaks, use
soapy water or liquid soap applied to
each of the connections. Any
bubbles formed indicate a leak.
Correct all leaks immediately.
IMPORTANT: The gas hose and
cylinder must ALWAYS be located well
behind the heater.
In order to reduce the risk of icing up
when operating at long periods at
maximum capacity, you should use a
larger capacity gas bottle, or two/
three bottles in parallel, as shown in
Fig 2.
• The ‘Tee’ piece and ‘pigtails’
are readily available from your
builders merchants or gas
supplier.
CHANGING GAS BOTTLES
1. Turn off the heater and disconnect from the electrical supply.
2. Close the gas valve on the bottle and unscrew the regulator, (left hand
thread).
3. Ensure the replacement bottle screw threads and gas orifice is perfectly
clean before screwing in the regulator valve tightly.
4. Check to ensure there are no leaks using soapy water and when satisfied,
plug in to the electrical supply and restart the heater.
Fig 1
Fig 2

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OPERATING SPACE AND AIR SUPPLY
MINIMUM FRESH AIR OPENING REQUIREMENTS
As a general rule of thumb, an opening of 1in2per 1000 Btu/hr is a minimum
requirement.
These heaters are specified as requiring a minimum ventilation of 3 sq/ft per
100,000BTU/hr.
OPERATING SPACE
Do not obstruct the air intake to the heater and allow the following
clearances from combustible surfaces.
Outlet: 8 feet (2.4 m)
Sides: 2 feet (0.6 m)
Top: 6 feet (1.8 m)
Rear: 2 feet (0.6 m)
Keep the heater as far as practical from propane tanks and never point the
heater directly at any propane tank.

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PRINCIPLE OF OPERATION
Understanding the basic operation of the heater will reinforce the need to
maintain the unit in top condition at all times, whilst always observing the
safety precautions.
The heater comprises four basic systems:
1. The gas system.
2. The air system.
3. The ignition system.
4. The safety control system.
AIR SYSTEM
An axial fan, which is energised when switching on, provides the air flow
through the combustion chamber to provide a stream of hot air from the
heater.
GAS SYSTEM
The gas supply to the machine is by means of a high pressure hose,
connected to an LPG (Liquid Propane Gas) cylinder, via a pressure regulator.
When the mains supply is switched on, the Safety Shut-off valve allows the gas
to flow to the Flame Failure Valve, and when the Failure Valve Override Knob is
depressed, gas flows to the burner head.

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IGNITION SYSTEM
Ignition is automatic with this heater as soon as the gas valve button is
depressed, with a continuous spark from the spark plug igniting the gas. As the
thermocouple heats up, a low voltage is fed to the Flame Failure Valve,
causing the valve to open, so that after a few seconds, the Gas ValveButton
may be released and the flame is established.
SAFETY CONTROL SYSTEM
Should the flame extinguish for any reason, the thermocouple will quickly cool,
causing the Flame Failure Valve to close, shutting off the gas supply.
Similarly, should there be a power failure, causing the fan motor to stop, the
Safety Shut-Off Valve will shut off the gas supply.
Additionally, the machine is equipped with thermal overload protection,
which will intervene should the unit overheat, shutting off the electrical supply.
STARTING PROCEDURE
1. Ensure there is sufficient gas and that it is correctly connected.
2. Open the supply valve on the gas
cylinder, and fully open the
regulator valve adjacent to the
gas inlet pipe.
3. Plug the heater in to a suitable
power supply.
4. Set the flame intensity control
valve (B), to a low setting,
5. Set the fan switch (A) to the ON (I)
position. Confirm the fan
operates.
6. Hold in the gas valve button (C), until the thermocouple is energised and
the heater ignites.
7. If the heater fails to ignite, there may be air in the hose so keep the gas
valve open and wait for about 15 seconds. Wait 30 seconds for unburned
fuel to exit the heater. Repeat the step above.
WARNING: BEFORE STARTING THE HEATER, YOU MUST ENSURE THAT THE
MINIMUM VENTILATION REQUIREMENTS ARE OBSERVED TO AVOID THE
RISK OF CARBON MONOXIDE POISONING.

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8. When the burner remains lit, set the heater at the required level by turning
the flame intensity control valve counter-clockwise. If the burner goes out,
turn off the gas. Turn the gas valve fully clockwise to its lowest position.
Check the fuel supply. If adequate fuel is available, re-start the heater from
step 1.
Should the flame extinguish when the ignition button is released, wait for 1
minute, before repeating the operation.
• Turning the flame intensity control valve anti-clockwise will increase the
gas supply and therefore the output, clockwise to decrease.
If ignition is difficult or irregular, ensure the fan is operating and that the air inlet
and outlet are completely clear. Also ensure that the electrode gap is correct,
and that the electrode is clean (see Maintenance)
Should the thermal overload protection feature operate and the spark plug is
seen to be operating, shut off the gas supply and allow the unit to cool for at
least 10 minutes with the fan running, before attempting to relight the burner.
Should the flame safety valve operate, the heater may be restarted once the
cause of the problem has been found and rectified.
SHUT-DOWN PROCEDURE
1. Turn off the gas at the propane cylinder valve(s).
2. Let the heater run while any gas left in the supply hoses is burnt off.
3. Allow the fan to run for 2 - 3 minutes with the burner off, in order to allow
the casing to cool down and the fan to disperse any residual gas.
4. Switch off the fan and unplug from the electrical supply.
5. Disconnect the gas supply.

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STORAGE
1. Store the propane gas cylinders in a safe manner outdoors and keep them
below 100 oF (37 oC).
2. Place protective bags over fittings & connectors and store in a clean, dry
place.
3. Fit the plastic cover caps which were removed when unpacking, over the
connections they covered when received.
4. When removing from storage, always check inside of heater for debris/
foreign objects before returning to use. Do not store the hose/regulator
inside the combustion chamber.
MAINTENANCE
It is essential that the heater is correctly maintained and kept in top condition
at all times.
All models are similar, in that access to the control components is gained by
removing the access panel under the base of the heater which is secured by
screws around the edge.
MONTHLY (WHEN IN CONSTANT USE)
Check the spark plug for cleanliness and correct operation. Have the gap re-
set to no more than 5mm by your Clarke service engineer.
Check the condition of the gas hose. If there are any signs of deterioration, it
should be renewed using only a Clarke original spare part.
Ensure that all connections are clean and secure.
When necessary, clean the fan and the inside of the heater thoroughly.
The use of parts other than genuine Clarke replacement parts may result in
safety hazards or decreased performance, and will invalidate your warranty.
CAUTION: DISCONNECT THE HEATER FROM THE PROPANE SUPPLY
CYLINDER(S)
WARNING: BEFORE CARRYING OUT ANY ADJUSTMENT OR
MAINTENANCE, ENSURE THE HEATER IS SWITCHED OFF, DISCONNECTED
FROM THE MAINS AND GAS SUPPLY, AND HAS BEEN GIVEN ADEQUATE
TIME TO COOL DOWN.

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TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Motor does not start. No power. Check power supply,
power cable and fuse,
and replace if necessary.
Faulty motor/capacitor. Fan
blades bent.
Check & replace if
necessary.
Lock out of appliance due
to overheating. Thermal cut-
out in operation.
Identify cause of over-
heating. Wait for 5 mins
and restart. If condition
persists, contact your
Clarke dealer for advice.
Spark plug does not
spark.
Gap incorrect, faulty
connection
Clean and reset gap if
necessary or replace.
Heater will not ignite Connection/installation
incorrect.
Check that installation
instructions are followed.
No spark at spark plug due
to loose HT lead or PCB
fault.
Check spark plug wire.
Tighten or re-attach if
loose. If condition persists,
contact your Clarke
dealer for advice.
Heater stops during
operation.
Excessive or insufficient gas
supply.
Check pressure regulator
& replace if necessary.
Check that fan motor
works properly.
Check, and use a larger
cylinder, or two or more in
parallel.
Check there are no
obstructions to air flow.
Check ventilation is
adequate. See also
‘Motor does not Start’.
No gas flow to the
burner.
Cylinder gas tap closed. Open the gas tap.
Cylinder is empty. Replace cylinder.
Nozzle is obstructed. Remove nozzle & clean.
Gas leaks from supply hose
or from tap.
Use soapy water to find
the leak and repair.

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SPECIFICATIONS
Please note that the details and specifications contained herein are correct
at the time of going to print. However CLARKE International reserve the right to
change specifications at any time without prior notice. Always consult the
heater’s data plate.
PROBLEM CAUSE REMEDY
Burner starts but stops
as the gas valve
button is released.
Thermocouple is not warm
enough or is faulty.
Repeat the starting
operation, keeping the
gas valve button
depressed for longer.
Weak gas supply. Increase flame intensity
control valve setting.
Model Number 900DV 1600DV 2100DV
Dimensions (L x W x H) mm 500x215x370 500x215x370 640x235x385
Weight 6.65 kg 6.7 kg 8.6 kg
Fuse Rating (230V only) 13A 13A 13A
Operating Voltage 230V 50Hz
1ph / 110V
50Hz
230V 50Hz
1ph / 110V
50Hz
230V 50Hz
1ph / 110V
50Hz
Rated Input Power 100W 110W 130 W
Rated Input 110V - 1.5A
220V - 0.75A;
110V - 1.5A
220V - 0.75A;
110V - 1.5A
220V - 0.75A;
Gas Consumption (kg/hr) 1.16-1.79 1.59-2.63 3.0-3.86
Air Flow (m3/hr) 535 580 690
Gas Pressure (max) 300mBar 300mBar 300mBar
Min Heat Output (kW/btu) 16.1/55,000 22/75,000 35/120,000
Max Heat Output (kW/btu 24.9/85000 36.6/125,000 50/170,000

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PARTS DIAGRAM - DEVIL 900DV / 1600DV

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PARTS LIST - DEVIL 900DV / 1600DV
No Description No Description
1 Outer Shell 20 Fuel Tube Assembly
2 Handle Mounting clips 21 Extension Fitting
3 Handle 22 Control Valve Assembly Nut
4 Middle Cylinder 23 Control Valve Assembly
5 Front Guard 24 Male Fitting Connector
6 Orifice Assembly 25 Solenoid Valve Assembly
7 Flame Holder Assembly 26 Solenoid Valve Assembly Nut
8 High Limit Switch Bracket 27 Flame Intensity Control Knob
9 High Limit Switch 28 Control Box
10 Spark Plug Nut 29 Dual Voltage Switch
11 Spark Plug Washer 30 Dual Voltage Switch Cover
12 Spark Plug 31 Power Switch
13 Fan 32 Bushing Strain Relief
14 Motor Assembly 33 Power Cord Assembly
15 Inlet Grille 34 Ignition Circuit Board
16 Thermocouple Bracket 35 Hose/Regulator Assembly
17 Thermocouple 36 Access Panel
18 Orifice Nut 37 Rubber Foot
19 Elbow Fitting

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PARTS DIAGRAM - DEVIL 2100DV

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PARTS LIST - DEVIL 2100DV
No Description No Description
1 Outer Shell 21 Elbow Fitting
2 Handle Mounting clips 22 Fuel Tube Assembly
3 Handle 23 Extension Fitting
4 Middle Cylinder 24 Control Valve Assembly Nut
5 Front Guard 25 Control Valve Assembly
6 Orifice Assembly 26 Male Fitting Connector
7 Flame Holder Assembly 27 Solenoid Valve Assembly
8 High Limit Switch Bracket 28 Solenoid Valve Assembly Nut
9 High Limit Switch 29 Flame Intensity Control Knob
10 Spark Plug Nut 30 Control Box
11 Spark Plug Washer 31 Dual Voltage Switch
12 Spark Plug 32 Dual Voltage Switch Cover
13 Fan 33 Power Switch
14 Motor Assembly 34 Bushing Strain Relief
15 Motor Mounting Bracket 35 Power Cord Assembly
16 Bracket 36 Ignition Circuit Board
17 Inlet Grille 37 Hose/Regulator Assembly
18 Thermocouple Bracket 38 Access Panel
19 Thermocouple 39 Rubber Foot
20 Orifice Nut

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WIRING DIAGRAMS