Cumberland VariFlame VF-16-OPS User manual

VariFlame™ Heater
Patent Pending
Models:
VF-16–OPS, VF-16–OPP, VF-16–OPG
VF-16–ONS, VF-16–ONP, VF-16–ONG
Owner’s Manual
PNEG-2091
Version 04
Date: 02-01-19
PNEG-2091

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-2091 VariFlame™ Heater

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
Electrical and environmental specifications .................................................................................16
Timing specifications .................................................................................................................17
Chapter 3 System Overview ....................................................................................................................19
Heater component functions ......................................................................................................19
Burner control module and sequence of operation .......................................................................21
Chapter 4 Installation ..............................................................................................................................23
Installing the air diverter.............................................................................................................23
Installing for recirculating operation (indoor) ................................................................................24
Wiring Diagrams and Schematics ...............................................................................................27
Pipe sizing guidelines ................................................................................................................32
Chapter 5 Startup and Operation .............................................................................................................35
Pre-startup inspections ..............................................................................................................35
Emergency heater shutdown......................................................................................................35
Normal heater shutdown............................................................................................................35
Starting the heater.....................................................................................................................36
Operating the burner .................................................................................................................36
Adjusting the heater output ........................................................................................................37
Chapter 6 Service and Maintenance ........................................................................................................39
Cleaning the heater ...................................................................................................................39
Guidelines for checking gas pressure .........................................................................................39
Checking the valve inlet pressure ...............................................................................................40
Checking the valve output pressure ............................................................................................41
Replacing the motor and fan wheel.............................................................................................42
Replacing the air proving switch .................................................................................................44
Replacing the Temperature High Limit Switch..............................................................................46
Replacing the Flame Probe........................................................................................................47
Replacing the Ignitor..................................................................................................................49
Replacing the control board .......................................................................................................50
Replacing the gas valve.............................................................................................................52
Chapter 7 Troubleshooting......................................................................................................................55
Troubleshooting ........................................................................................................................55
Chapter 8 Parts........................................................................................................................................59
VariFlame Controller Parts .........................................................................................................59
Switch and Probe Parts .............................................................................................................60
Gas Parts .................................................................................................................................61
Motor and Blower Wheel Parts ...................................................................................................62
GSI Group, LLC Limited Warranty ...........................................................................................63
PNEG-2091 VariFlame™ Heater 3

NOTES
4PNEG-2091 VariFlame™ Heater

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
PNEG-2091 VariFlame™ Heater 5

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-2091 VariFlame™ Heater

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
PNEG-2091 VariFlame™ Heater 7

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-2091 VariFlame™ Heater

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
PNEG-2091 VariFlame™ Heater 9

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-2091 VariFlame™ Heater

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-2091 VariFlame™ Heater 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-2425
Warning Electrical Hazard
Instructions
Wiring Diagram
On heater frame DC-2427
Danger: Suffocation Hazard
Warning: Electrical, Fire, and
Heat Hazard
Notice
12 Pneg-2091 VariFlame Heater

Chapter 1: Safety Precautions
Location Decal No. Decal Description
On Door DC-2429 Caution
On Door DC-2430 Warning: Hot Surface
Over Heater
Outlet Cover DC–2457 Warning: Fire Hazard
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-2091 VariFlame Heater 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-2091 VariFlame™ Heater

2Specifications
Topics Covered in this Chapter
▪ VariFlame vapor propane specifications
▪ VariFlame natural gas specifications
▪ Electrical and environmental specifications
▪ Timing 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-2091 VariFlame™ Heater 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 4.0 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)
Electrical and environmental specifications
Table 2-1 Electrical and environment specifications
Inputs
Supply Input : 120Vac, -15% +10%, 50/60Hz ±5%, 1 phase, 978W
AIR SW Inputs (AIR SW): 24Vac, 50-60Hz, 200uA
HI LIMIT SW Inputs (HI LIM SW): 24Vac, 50-60Hz, 500mA min
Flame Sensor Input (FLM SNS) 0-5Vdc, 120uA
Outputs
FAN output (FAN and FAN RTN) 120Vac, 50-60Hz, 5A max. PF: 0.5
IGN output (IGN and IGN RTN) 120Vac, 50-60Hz, 2A max.
Gas Valve activation output (Main Valve) 24Vac, 50-60Hz, 400mA max. PF: 0.80
24Vac Out 24Vac, 400mA (transient and use on White-Rodger valve only)
Gas Valve control output (0-20V Valve)
(use on Honeywell valve only) 0-20Vdc, 250mA
16 PNEG-2091 VariFlame™ Heater

Chapter 2: Specifications
Table 2-1 Electrical and environment specifications (cont'd.)
Gas Valve control output (Stepper RX)
(use on White-Rodger valve only) 0-5Vdc, 1mA
Variflame Controller - Environment Specifications
Environment type Indoor use only
Pollution Degree 2
Installation Category or overvoltage
category III
Protection against electric shock
classification Class 1
Altitude 2000 Meters Max. (6561 Ft. Max)
Humidity (maximum relative) operating
-40 to 0°C (-40 to 32°F) Non condensing
0 to 10°C (32 to 50°F) Non condensing
10 to 30°C (50 to 86°F) 95 % (± 3 %) Non condensing
30 to 65°C (86 to 149°F) 95 % (± 3 %) Non condensing
Operating Temperature -40 to 65°C (-40 to 149°F)
Controller safety characteristics
The controller is Safety Class I according to IEC classification and has been designed to meet the stand-
ard requirements of ANSI Z21.20-2014 CAN/CSA-C22.2 No. 60730-2-5-14 (Automatic electrical controls
for household and similar use — Part 2-5: Particular requirements for automatic electrical burner control
systems, (IEC 60730-2-5:2000+A1:2004+A2:2008, MOD)). It is an Installation Category III intended for
operation from a normal single phase supply.
Timing specifications
Values
Parameter Symbol Description Unit Min Typical Max
Flame detector
response time TFLDR
Period of time between the loss of
the sensed flame and the signal
indicating the absence of flame
ms 550 -2000
Flame detector
self-checking
rate
RFLDSC
Frequency of the self-checking
function of the flame detector (in
number of operations per unit of
time)
Time
per
hour
1620 1800 1980
Ignition time TIG Period of time during which the
ignition device is energized ms 14580 16200 17820
Main flame
establishing
period
TMFLESP
Period of time between the signal
to energize the main fuel flow
means and the signal indicating
presence of the main burner flame
ms 0-275
Pre-ignition
time TPRIG
Period of the ignition time between
the signal to ignite and the signal to
energize the fuel flow means
ms 11430 12700 13970
PNEG-2091 VariFlame™ Heater 17

Chapter 2: Specifications
Values
Parameter Symbol Description Unit Min Typical Max
Post-purge
time TPOPG
Purge time that takes place imme-
diately following the shutting off of
the fuel supply
ms 4950 5500 6050
Recycle time TRE
Period of time between the signal
to de-energize the fuel flow means
following the loss of flame and the
signal to begin a new start-up
procedure
ms 4500 -9000
Start-up lock-
out time TSTLCKO
Period of time between the signal
to energize the fuel flow means
and lock-out. For systems which
control two separate fuel flow
means, two different start-up lock-
out times are possible (first and
second start-up lock-out times).
ms 0-1000
Valve open
period / Trial-
for-ignition
period
TTRIGP
For multi-try systems, the period of
time between the signal to ener-
gize the fuel flow means, and the
signal to de-energize the fuel flow
means, if proof of the supervised
burner flame is not established. In
the USA, this period is referred to
as the “trial-for-ignition period”. ms 3870 4300 4730
The period of time between ener-
gizing and de-energizing the fuel
flow means, if proof of the super-
vised flame is not established. For
systems incorporating interrupted
pilot ignition – also considered
main burner flame establishing
period.
Valve
sequence
period
TVLSQ
For multi-try systems, the sum of
all valve opening periods prior to
lock-out, if proof of the supervised
burner flame is not established
ms 11610 12900 14190
Inter-purge
time TINPG
On a multitry system, the purge
time that takes place between the
end of a trial for ignition period and
reactivation of the ignition means if
proof of the supervised flame is not
established.
Inter-purge time is normally pro-
vided for burners where air for
combustion is mechanically intro-
duced for ventilation of the com-
bustion chamber and flue
ms 4950 5500 6050
18 PNEG-2091 VariFlame™ Heater

3System Overview
Topics Covered in this Chapter
▪ Heater component functions
▪ Burner control module and sequence of operation
Heater component functions
Figure 3-1 VariFlame Components
1 — Blower motor and wheel assembly
2 — High Limit Switch
3 — Air Proving Switch
4 — Igniter
5 — Flame Probe
6 — Control Board
7 — Throttle Valve
8 — Gas Valve
Blower motor and wheel assembly (1)
The blower motor and wheel assembly provides all of the airflow in the heater. It is important to ensure
that the blower wheel is spinning in the correct direction, and that the blades of the wheel stay clean. Any
reduction in airflow can cause a reduction in burner efficiency and overall heater performance.
PNEG-2091 VariFlame™ Heater 19

Chapter 3: System Overview
High Limit Switch (2)
WARNING
Never bypass the high limit switch. Bypassing the limit switch can cause the heater
to overheat.
The high limit switch is a “normally closed” thermostat switch that limits the outlet temperature of the
heater. If the outlet temperature of the heater ever reaches the temperature limit of the high limit switch,
the switch opens and the heater will go into lockout mode. A small manual reset button is located on the
back of the switch and must be pushed to reset the high limit switch anytime it is tripped. It is important to
investigate the source of the high temperature trip, as this is not normal. Typical sources of high limit
faults are a dirty blower wheel, restricted inlet, restricted outlet, and excess gas pressure.
Air Proving Switch (3)
The air proving switch is a “normally open” paddle switch that is used to sense when the blower wheel is
providing airflow. When enough airflow is being driven, the paddle of the limit switch will force the limit
switch to a closed state. If the switch is in a closed state when the blower is off, or the switch is in an open
state when the blower is on, the heater will go into lockout mode. Typical sources of air proving switch
faults are dirty blower wheel, restricted inlet, restricted outlet, and a dirty air proving switch.
Igniter (4)
The igniter is a hot surface heating element used to initiate combustion. The igniter runs off of 120VAC,
and has a short “pre-heat” period before the gas is turned on by the heater. When the igniter is operating
properly, it should glow red when power is supplied to it. Typical sources of igniter failure include improper
handling, improper maintenance, and shorting out to the burner.
Flame Probe (5)
The flame probe is a sensor that allows the burner control to sense when a flame is present. A flame will
create a small micro-current between the burner and the flame probe rod that is then sent to the control
board. Typical sources of flame probe failure are a bad ground or dirty flame probe.
Control Board (6)
The control board acts as the main control of the heater. The control board controls all of the heater com-
ponents and is responsible for making all safety related decisions. Any time the heater goes into “lockout”
mode, power to the control board must be cycled. Typical sources of control board failure include
improper power supply, shorted heater components, and improper maintenance.
Throttle Valve (7)
The throttle valve is a manually adjustable valve located between the main gas valve and the burner ori-
fice. The throttle valve is used to manually adjust the heater output. When the handle of the valve is paral-
lel with the pipe, the valve is in the “full open” position. A decal on the inside of the door shows the heater
output based on valve position, and should be referenced when making any adjustments.
Gas Valve (8)
The gas valve is used to turn on and off gas to the burner as well as control gas pressure. When powered,
the 24VAC solenoid located inside the valve, allows gas to flow. Typical sources of gas valve failure are
incorrect inlet gas pressure, dirty fuel, and improper maintenance.
20 PNEG-2091 VariFlame™ Heater