Nortek BENSON VRA-4 12 Guide

1610VRA4‐AMEN,p.1/24
Gas‐fired,balancedflueor
power‐ventedunitheater
VRA‐4
12,20,30,35,45,50,
60,75,100,120,145
ThisappliancemeetsthefollowingECDirectives
DIR2009/142/EC:GAD
DIR2004/108/EC:EMC
DIR2006/95/EC:LVD
DIR2006/42/EC:MD
INSTALLATION–COMMISSIONING–SERVICING‐USER
INSTRUCTIONS
Pleasereadthisdocumentcarefullybeforecommencinginstallationcommissioningand/orservicing.
Leaveitwiththeuserorattachedtotheapplianceorgasservicemeterafterinstallation.

ATTENTION
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,
injuryordeath.Allworkmustbecarriedoutbyappropriatelyqualifiedpersons.Themanufacturerdoes
nottakeanyresponsibilityintheeventofnon‐observanceoftheregulationconcerningtheconnection
oftheapparatuscausingaharmfuloperationpossiblyresultingindamagetotheapparatusand/or
environmentinwhichtheunitisinstalled.

1610VRA4‐AMEN,p2/24
TABLEOFCONTENTS


1.0INTRODUCTION   p3
1.1 BasicInformation
1.2 Warranty

2.0TECHNICALDATA   p4
2.1 Specifications
2.2 Dimensions

3.0GENERALREQUIREMENTS  p6
3.1 RelatedDocuments
3.2 HeaterLocation
3.3 CombustionAirInletPipeandFluePipe
3.4 AirSupply
3.5 AirDistributionSystem
3.6 ElectricalSupply
3.7 GasSupply

4.0INSTALLATION   p9
4.1 UncratingandPreparation
4.2 SuspendingtheHeater
4.3 FittingtheCombustionAirInlet/FluePipe
System
4.4 GasConnection
4.5 ElectricalConnections
4.6 RoomThermostatSiting

5.0AIRDISTRIBUTION   p11

6.0COMMISSIONINGANDTESTING  
p11
6.1 ElectricalCheck
6.2 GasConnection
6.3 SuspensionandSupport
6.4 LightingtheHeater
6.5 Heaterpipework
6.6 Adjustments
6.7 AirDistributionSystem
6.8 HeaterControls
6.9 HandingOver

7.0SERVICINGINSTRUCTIONS  p14
7.1 ServicingProcedure

8.0REMOVALANDREPLACEMENTOFPARTSp15
8.1 MainBurnerRemoval
8.2 MainBurnerInjectors
8.3 IgnitionSystem
8.4 OperatingGasValve
8.5 LimitControls
8.6 CombustionAirPressureSwitch
8.7CombustionAirFan

9.0FAULTFINDING   p17

10.0PARTSLIST   p20

11.0GASCONVERSION   p20

12.0USERSINSTRUCTIONS   
p21

13.0HEALTH&SAFETYSTATEMENT  
p22




HAZARDINTENSITYLEVELS

DANGER
Failuretocomplywill resultinseverepersonalinjuryordeathand/or
propertydamage.
WARNING
Failuretocomplycould resultinseverepersonalinjuryordeathand/or
propertydamage.
CAUTION
Failuretocomplycouldresultinminorpersonalinjuryand/orproperty
damage.





1610VRA4‐AMEN,p3/24

WARNINGS


WARNINGS
Foryoursafety,ifyousmellgas:
Donottrytolightanyappliance
Donottouchanyelectricalswitch,donotuseanyphoneinyourbuilding
Evacuateallpersonnel&contactyourgassupplierimmediately
Donotstoreorusepetrolorotherflammablevapoursandliquidsinthevicinityofthe
appliance.
Improperinstallation,adjustment,alteration,serviceormaintenancecancause
propertydamage,injuryordeath.Readtheinstallation,operationandmaintenance
instructionsthoroughlybeforeinstallingorservicingthisequipment.
Donotusethisapplianceifanyparthasbeenimmersedinwater.Immediatelycalla
qualifiedservicetechniciantoinspecttheapplianceandreplaceanygascontrolthat
hasbeenimmersedinwater.
Thisapplianceisnotintendedforusebypersons(includingchildren)withreduced
sensoryormentalcapacitiesorlackofexperienceandknowledgeunlesstheyhave
beengivensupervisionorinstructionsconcerninguseoftheappliancebyaperson
responsiblefortheirsafety.
Childrenshouldbesupervisedtoensurethattheydonotplaywiththeappliance.
Shouldoverheatingoccurorthegassupplyfailstoshutoff,shutoffthemanualgas
valvetotheappliancebeforeshuttingofftheelectricalsupply.
Gas‐firedappliancesarenotdesignedforuseinhazardousatmospherescontaining
flammablevapoursorcombustibledust,inatmospherescontainingchlorinatedor
halogenatedhydrocarbonsorinapplianceswithairbornesiliconesubstances.
Themanualshouldbekeptinasafeplaceforfuturereference.
Unauthorisedmodificationofthisapplianceordeparturefromuseinthemanner,for
whichitwasintendedbythemanufacturerorinstalledinamannercontrarytothese
instructions,mayconstituteahazardandjeopardizeallwarranties.
Deviationsshouldonlybecarriedoutafterformalconsenthasbeenobtainedfrom
themanufacturer.
Theelectricalisolatorshouldonlybeusedinanemergencyandshouldnotbeused
for closingdownthemainburner,asitswitchesoffthefanprematurelyandmay
damagetheheatexchanger,invalidatingthewarranty.
Useonlyfactory‐authorizedpartswhenreplacementisrequired.
Incaseofpersistingproblems,contactyourdistributor




 INTRODUCTION
1.1BasicInformation

TheinstructionsinthismanualapplytoModelVRA‐4gas‐fired/fan‐assistedwarmairheaters.These
modelshaveanaxialfanforairdelivery.Theseheatersaredesignedforoverheadsuspensionandare
suitableforindoorinstallationonlyinstalledatanoperationambienttemperaturebetween‐15°Cand
45°C.
WheninstalledasatypeC12/C32andwheretheheightabovefloorlevelisgreaterthan1,8metres
measuredtotheundersideoftheappliancetheymaybeusedasagarageairheater.Thisappliancemust
beinstalledinaccordancewiththerulesinforce.
Beforeinstallation,checkthatthelocaldistributionconditions,natureofgasandpressureand
adjustmentoftheappliancearecompatible.Apermanentelectricitysupplyof230volts,50Hz,single
phaseisrequired.

Heatersareapprovedfor: TypeC12‐horizontalventforbalanced‐flueheaters;
    TypeC32‐verticalventforbalanced‐flueheaters;
    TypeB22‐verticalvent;
    CategoryII2H3+forGBandIE

1

1610VRA4‐AMEN,p4/24

Whentheexternalcontrolcallsforheat,anelectroniccontrolbeginstheignitionsequencetoprovideforasafe
start.About30secondsafterthecallforheat,thefanwillbegincirculatingwarmair.Theelectroniccontrolwill
supervisetheflameduringtheentireheatingcycletoensuresafeoperation.Whentherequiredroom
temperatureisreached,themainburnerwillshutdownleavingthefanrunningtocooldowntheheat
exchanger.Afterapproximately45seconds,thefandelayrelaywillturnoffthefan.

1.2Warranty
Warrantyisvoidif:









  TECHNICALDATA


2.1Specifications
Table1
VRA-4 12 20 30 35 45 50 60 75 100 120 145
Gas category
Comb. Air & Flue, type B
(1)
Comb. Air & Flue, type C
(1)
Connection collars mm 80 100 100 130 130 130 130 130 130 130 130
Heat input Hs kW 13,33 26,42 31,63 43,95 54,38 61,08 73,25 87,85 114,87 144,81 165,47
Heat input Hi kW 12,00 23,80 28,50 39,60 49,00 55,00 66,00 79,15 103,50 130,40 149,00
Heat output kW 11,14 21,82 25,99 36,23 44,64 50,77 60,92 73,13 94,50 119,32 137,39
Thermal Efficiency % 93,00 92,00 91,00 92,00 91,00 92,00 92,00 92,00 91,00 92,00 92,00
m³/h 1,27 2,52 3,02 4,19 5,19 5,82 6,98 8,38 10,95 13,80 15,77
Gas consumption G25 m³/h 1,48 2,93 3,51 4,87 6,03 6,77 8,12 9,74 12,74 16,05 18,34
Gas consumption G31 kg/h NA 1,86 2,22 3,09 3,82 4,29 5,15 6,17 8,24 10,17 11,62
Gas pipe connection
(2)
Real temperature rise
(3)
K 3031333331303429293235
Air flow measured
(3)
m³/h 1100 2000 2300 3200 4300 5000 5200 7300 8000 10800 11400
Nominal motor speed RPM 1380 1260 920 910 920 930 900 890 860 890 890
Recommended mounting height
(4)
m 2,53444455566
Horizontal throw
(5)
m 9,5 13 17 24 25 27 30 32 31 38 39
Sound Pressure
(6)
dB(A)3642374645454748525456
Sound Pressure
(7)
dB(A)4349445352525455596163
Electrical service (protection IP20)
Total electrical rating W 530 360 250 370 370 540 760 760 850 1730 1730
Weight kg 59 59 64 94 99 114 114 126 184 242 279
II2H3+
B22P
C12, C32, C62
1/2" 3/4"
Gas consumption G20
230/240V 1N ~ 50Hz


a) VRA-4 heaters are installed in atmospheres containing flammable vapors or
atmospheres containing chlorinated or halogenated hydrocarbons or atmospheres
containing any silicone, aluminum oxide, etc., that adheres to spark ignition flame
sensing probes.
b) The installation is not in accordance with these instructions.
c) Axial fan-type unit heater is connected to a duct system or fitted with a non
authorized air distribution device.
2
(1) Gas appliance Classifications for approved venting methods based on CEN report CR 1749:2001.
(2) There is a difference between the gas connection diameter and the diameter of the supply line. Always use the most adequate diameter of the supply line
to minimize the pressure drop through the gas pipes – if necessary, reduce the diameter of the supply line at the inlet of the unit.
(3) Figure for isothermal conditions.
(4) Height from floor to bottom surface of heater. These are recommendations only. Positioning of the unit heaters for proper performance is application
dependent. Operation is affected by other air moving equipment in the space, obstructions to the air flow, draughts and/or close proximity to doors or
windows etc. Care should be taken to avoid mounting the heaters above these recommendations unless downturn nozzle options are used as significant
stratification may occur resulting in poor floor coverage and higher energy losses through the roof structure.
(5) Isothermal conditions at 20°C ambient air temperature, discharge louvre zero deflection, v = 0.5m/s. The air flow will be influenced by the height of the
building, mounting height of the unit, ambient temperature & adjustment of the louvers.
(6) Sound pressure level in dB(A) in free field conditions, measures at 5 meters from the unit.
(7) Sound pressure level in dB(A), measures at 5 meters from the unit with A = 160m² and Q=2

1610VRA4‐AMEN,p5/24
K
L
S
R
N
M
P
Q
D
Flue Outlet
D
Flue Inlet
W
Gas Connection
1
Table2A:InjectorsizeandburnerpressureG20naturalgas(Inletpressure=20.0mbar)
Table2B:InjectorsizeandburnerpressureG30/G31butane/propane(InletpressuresG30=28mbar‐G31=37mbar)
V
RA-4 12 20 30 35 45 50 60 75 100 120 145
Quantity 5 6 8 10 8 8 10 12 10 12
mm 1,15 1,15 1,15 1,15 1,4 1,45 1,45 1,5 1,95 1,9
marking 115 115 115 115 140 145 145 150 195 190
butane N.A. 28,1 28,1 28,4 28,14 27,9 27,75 26,96
propane 35,80 35,80 36,20 35,90 30,10 35,60 35,40 34,40 30,70 30,60
Injector size
Burner pressure (mbar) (1)


1)withopenservicedoor
2.2Dimensions

250 min J
I C 30
2

F
150
150
E
150 A 500 min
GH
B

T V
19
U
51
3

VRA-4ABCDEFGH I JKLMNPQRSTUVW
12 965 567 652 80 71 531 130 305 100 782 334 280 87 106 345 444 122 221 123 611 406 1/2"G
20 965 567 652 100 71 531 130 305 103 785 334 280 87 106 345 444 122 221 123 611 406 1/2"G
30 965 567 652 100 74 531 94 370 139 821 334 280 87 106 345 444 122 221 123 611 406 1/2"G
35 965 845 652 130 74 531 154 517 138 824 331 420 82 175 508 720 134 211 123 611 406 3/4"G
45 965 845 652 130 74 531 117 605 138 824 331 420 82 175 508 720 134 211 123 611 406 3/4"G
50 1298 845 652 130 151 759 154 517 156 838 409 425 82 175 508 720 135 212 123 942 406 3/4"G
60 1298 845 652 130 151 759 154 517 139 824 409 425 82 175 508 720 135 212 123 942 406 3/4"G
75 1298 845 652 130 151 759 117 605 139 824 409 425 82 175 508 720 135 212 123 942 406 3/4"G
100 1298 954 807 130 151 759 73 808 301 1022 479 477 82 180 608 833 212 212 123 942 550 3/4"G
120 1750 980 846 130 67 1100 164 602 177 1057 348 490 90 175 595 795 160 256 20 1365 770 3/4"G
145 1750 1150 846 130 67 1100 173 692 177 1057 348 570 90 177 736 936 160 256 20 1365 770 3/4"G

1 Electrical connections
2 Service panel
3 Suspension points (M10 female)
Figure1
VRA-4 1220303545506075100120145
Quantity 5568108810121012
mm 1,5 2,1 2,1 2,2 2,2 2,4 2,7 2,7 2,9 3,4 3,4
marking 150 210 210 220 220 240 270 270 290 340 340
Burner pressure (mbar) (1)
8,1 8 7,25 7,1 6,9 9,2 8,5 8,3 7,5 9,2 9
Injector size

1610VRA4‐AMEN,p6/24
  GENERALREQUIREMENTS

3.1Relateddocuments

Itisimportantthatallgasappliancesareinstalled
inaccordancewiththerulesinforceandby
appropriatelyqualifiedpersons.Failuretoinstall
appliancescorrectlycouldleadtoprosecution.Itis
inyourowninterestandthatofsafetytoensure
compliancewiththelaw.

Airheatersshouldnotbeinstalledin
corrosiveatmospheres,i.e.nearplatingor
degreasingplantsorinareaswherethere
isafirerisk.
Donotlocatetheairheaterwhereitmay
beexposedtowaterspray,rain,etc.
3.2Heaterlocation

Thelocationchosenfortheairheatermustpermittheprovisionofasatisfactoryfluesystemventingto
outdooratmosphereandadequatelyventilatedtoprovideforcombustionair.Thelocationmustalso
providesufficientspacetoallowtheheatertobeserviced.

Table3Minimuminstallationclearances(mm) Table4Recommended mountingheights(m)(*)
VRA-4 mm
Top 150
Flue connector 150
Access panel 800
Non access side 150
Bottom 150
Rear* 450

*Measurerearclearancefromthebackofthemotor
VRA-4 12 20 30→-50 60-→100 120→145
Mounting
height 2,5 3 4 5 6


*Heightfromfloortobottomsurfaceofheater.Theseare
recommendationsonly.Positioningofheatersdependson
application.
Airheatersshould,whereeverpossiblealwaysbeinstalledtoblowtowardoralongexternalwall
surfaces.Wheretwoormoreairheatersareinstalledinthesameroom,ageneralschemetoensure
continuousaircirculationshouldbemaintainedforbestresults.Suspendedheatersaremosteffective
whenlocatedasclosetotheoccupancyzoneaspossible,thisfactshouldbeborninmindwhen
determiningthemountingheightstobeused.Careshouldbeexercisedtoavoiddirectingwarmair
directlyontotheoccupants.Partitions,columns,counters,storageracking,etc.shouldbetakeninto
accountwhenchoosingthelocationsothatanunobstructedpathfortheaircirculationcanbe
maintained.Whereairheatersarelocatedinthecentreofthespacetobeheated,theairshouldbe
dischargedtowardoutsidewalls.Inlargeareas,theyshouldbelocatedtodischargeairalongoutside
wallswithadditionalheatersprovidedtoblowairintothecentreofthearea.Inplaceswhereinfiltration
ofcoldisexcessive,suchasentrancedoorsitisdesirabletolocateaheatersothatwarmairis
dischargeddirectlytowardthesourceofcoldairfromadistanceof4,5‐6,0metres.

3.3Combustionairsupply&fluesystem

Theairheatermaybeinstalledasabalancedflue
(TypeC)heaterrequiringbothacombustionair
inletductandafluepipeorasapowervented
(TypeB)heater,whichrequiresonlyafluepipe
exhaustingtooutdoors.Allproductsofcombustion
mustbefluedtooutdooratmosphere.Eachheater
installedasatypeBappliancemustbefittedwith
anindividualfluepipeandthecombustionairinlet
openingmustbeprovidedwithaprotectiongrill
(askyourdistributorfortheappropriateprotection
grill(IP20)(dia130=PN0225094).Eachheater
installedasatypeCappliancemustbefittedwith
anindividualcombustionair/fluepipesystem.
Onlysystemsspecifiedbytheairheater
manufacturermaybeused.Commonflueand
combustionairsystemsmustnotbeused!
Figure2a:Combustionairandfluepipesockets
1
2
3
4

1Flueoutletsocket
2Combustionairinletopening
3Gasconnectioninletwithsealingring
4Electricalconnections


IMPORTANT:Thefluemustbeinstalledinaccordancewithnationalandlocalregulations.Failureto
provideproperflueingcouldresultindeath,seriousinjuryand/orpropertydamage.Theairheater
mustbeinstalledwithafluetotheoutsideofthebuilding.Safeoperationofanypowerventedgas
apparatusrequiresaproperlyoperatingfluesystem,correctprovisionforcombustionair,andregular
maintenanceandinspection.
3

1610VRA4‐AMEN,p7/24

3.3.1Fluesforpowerventedinstallations(TypeBappliances)
IftheairheateristobeinstalledasatypeBappliance,airforcombustionwillbetakenfromwithinthe
spacewheretheheaterisinstalled.Ensurethatanadequateairsupplyforcombustionandventilationis
providedwithinthebuildinginaccordancewiththeregulations&rulesinforce.

Table5showsfluepipesizesandmaximum
pipelengths.Theminimumfluelengthis0.5
metres.Singlewallfluepipesarerequired.
Alljointsmustbesealedtopreventproducts
ofcombustionfromleakingintothebuilding.
Anapprovedflueterminalisrequired.

Ifthefluepassesthroughacombustible
elementofthebuildingitmustbeenclosed
byasleeveofnon‐combustiblematerialand
separatedfromthesleevebyatleasta25
mmairbreak.

Table5:Fluepipediameters&maximumlengths
VRA-4 12 35->145
Heater socket &
pipe dia
Equivalent length m
of 45° elbow
mm
m
Equivalent length
of 90° elbow
Maximum straight
length m
0.75
1.5
80
9
20, 30
100 130
Thetemperatureofanycombustiblematerialneartothefluemustnotexceed65°Cwhentheheaterisin
operation.Thefluemustbeatleast50mmawayfromanycombustiblematerial.Singlewallfluepipe
exposedtocoldairorrunthroughunheatedareasmustbeinsulated.Wherecondensationis
unavoidable,provisionmustbemadeforthecondensationtoflowfreelytoapointtowhichitcanbe
released,i.e.adrainorgully.Thecondensationdrainfromthefluemustbeconstructedfromnon‐
corrodiblematerialnotlessthan20mmdiameter.Copperorcopperbasedalloysmustnotbeusedfor
condensationdrains.

3.3.2Combustionairinletpipe&fluepipeforbalancedflueinstallation(TypeCappliances)
Balancedflueairheatersaredesignedtobefittedwitha
combustionairinletpipethatobtainsoutdoorairanda
fluepipethatexhaustsflueproductstooutdoors.
Airheatersiffittedwithapowerventerpermittingeithera
verticalorhorizontalcombustionairinlet/fluepipesystem.
Theheatersmustbeinstalledwithaconcentricverticalor
horizontalflue/combustionairinlet.Theheatersareonly
approvedforusewheninstalledwiththeappropriate
approvedconcentricventterminal.Seetable6.
Boththeflueandcombustionairpipesmustbesealed.
Usegasketsealedseamlessaluminiumpipeorequivalent.
Thefluepipemustincludeare‐sealabletestporttoallow
goodaveragesamplingofthefluegasmixturefortesting,
theportmustbeatleast450mmawayfromtheairheater
flueconnectionsocket.
Figure2b:
Combustionairandfluepipesockets,TypeC
1Flueproductsflueoutletsocketforfluepipe
2Combustionairinletopening

Followanyfluepipemanufacturers’
installationinstructionsformaking
joints,includingconnectionstotheair
heater,forpassingthroughabuilding
elementandforsupportrequirements.If
morethanoneairheaterisbeing
installedinthesameplaceeachheater
musthaveaseparatefluesystem.
Wherecondensationisunavoidable,
provisionmustbemadeforthe
condensationtoflowfreelytoapointto
whichitcanbereleased,i.e.adrainor
gully.Thecondensationdrainfromthe
fluemustbeconstructedfromnon‐
corrodiblematerialnotlessthan20mm
diameter.Copperorcopperbasedalloys
mustnotbeusedforcondensation
drains.

Table6
Combustionairinlet&fluepiperequirements
VRA-4 12 35 -> 145
Flue pipe 80 130
Inlet pipe 80 130
Flue pipe
Inlet pipe
Flue pipe
Inlet pipe
Flue pipe
Inlet pipe
0,75
0,75
Max. straight
length m
20, 30
100
100 9
9
Equivalent length
of 45° elbow
Equivalent length
of 90° elbow
m
m1,5
1,5
Heater socket
& pipe dia mm

Concentric vertical vent or wall terminal : Mugro/Burfix dia 130
Concentric horizontal vent or roof terminal : Mugor/Burfix dia 130

1610VRA4‐AMEN,p8/24

3.4Airsupply

Itisimportanttoensurethatthereisanadequate
airsupplyatalltimesforbothcombustionand
heatingrequirements.
Modernconstructionsinvolvethegreateruse
ofinsulation,improvedvaporbarriersandweather
proofing.Thispracticemeansthatbuildingsare
sealedmuchtighterthaninthepast.

Thecombustionairsupplyforapowerventedgas
firedairheater(TypeBinstallation)canbeaffected
bylackofairsupply.Naturalinfiltrationmaynotbe
adequate.Useofextractfansaggravatesthis
situation.Itisimportanttoensurethatthereisan
adequateairsupplyatalltimes.Relianceondoors
andwindowsisnotallowed.Alwaysensurethatan
adequateinletforfreshairforcombustionis
providedsizedtosuitthetotalinstallationofany
combustionapparatus.

Fitanaccessguardtothecombustionairinleton
thebackoftheheaterandtakeappropriateaction
toensurethatitremainsunblocked.Seefigure2c.



WARNING:Thismodelairheateris
installedasatypeBapplicationandis
designedtotakeairforcombustionfrom
thespaceinwhichitisinstalled.Donot
restrictthecombustionairintake.
Figure2c:
Combustionairandfluepipesockets,TypeB

1combustionproductsflueoutletsocket
2combustionairinletopening
3Protectiongrill(option)(PN0225094)

3.5Airdistribution

Followrecommendedpracticeforbuildingairdistribution.Thefollowingnotesareofparticular
importance:
"Wherefreeblowingairheatersareinstalleditmustbetakenintoaccountthatheatedairisbuoyantwhenitleavesthe
appliance,therefore,airpatternswithinthespacebeingheatedwillmodifytheairthrowpatternachieved.
Inbuildinghavinglowheatlosswheresingleheatersarerequiredtocoveralargefloorareaandinbuildingswithhigh
ceilingheights,airre‐circulationfansmaybefittedtoensureevenheatdistributionandminimizestratification.Care
shouldbetakentoavoidimpedingairflowwithstorageracking,partitions,etc."

3.6Electricalsupply

Wiringexternaltotheairheatermustbecarriedoutinaccordancewiththerulesinforceandby
appropriatelyqualifiedpersons.Aconstant230Volt50Hertzsinglephasefusedelectricitysupplywith
neutrallinkisrequired.Allheatersandcontrolsmustbeearthed.Alockableisolatorwithcontact
separationofatleast3.0mmonallpolesshouldbeinstalledadjacenttotheapplianceandwithinreach
ofanypersonworkingontheheater.
Whenanumberofheatersaretobeconnectedaspartofasingleinstallationeachheatermustbe
providedwithaseparateisolator.
Theelectricalconnectiontotheairheaterisatthebackoftheappliance.Thefinalconnectionmustbe
madeintheterminalsprovidedinthecontrolcompartment.Followthewiringdiagramprovidedwiththe
airheater.
Electricalsupplycableconductorsizeshouldbe1.5mm.Fitthecordgripsuppliedwiththeheater.The
lengthofconductorsbetweenthecordgripandtheterminalsmustbesuchthatintheeventthatthe
cablebecomestautthelineconductorsdosobeforetheearthconductor.

3.7Gassupply

VRA‐4airheatersaredesignedtooperateoneithernaturalgas(G20)orpropanegas(G31).Refertothe
specificationsinsection2ofthisdocumentandtothedataplatefordetailsofsupplypressures.Thegas
meterandgasservicemustbecheckedbythesupplyundertakingtoensurethattheyareadequateto
dealwiththetotalloadofallgasfiredapparatusinstalled.

1610VRA4‐AMEN,p9/24
INSTALLATION


4.1Unpackingandpreparation

Priortodispatch,theairheaterwasoperatedandtestedatthefactory.Iftheheaterhasincurredany
damageinshipment,fileareportclaimwithin2workingdaysfromreceipt.
Checktheshippinglabelanddataplatetoensurethespecificationofgasandelectricalsuppliesare
compatible.Readthisdocumentandbecomefamiliarwiththeinstallationrequirementsandthe
appliancebeforecommencinginstallation.

4.2Suspendingtheairheater

Beforeinstallingtheappliance,checktoensure
thatthesupportingstructureisadequateto
carrytheweightoftheapplianceandits
ancillariesi.e.fluesystem.Consulttable1for
weightdata.
Whentheheaterisliftedforsuspension,
supportthebottomoftheheaterwithplywood
orotherappropriatelyplacedmaterial.Ifthe
bottomisnotsupported,damagecouldoccur.
Theheaterissuppliedwithfourpoint
suspension.Allpointsmustbeused.Two
threadednutretainersareprovidedoneach
sideofthetopoftheheater.Seedimensionsin
section2.2andfigure3.Besurethatthethreaded
hangerrodsarelockedtotheheaterasillustrated.
Recommendedmaximumhangerrodlengthis1.8m.
IMPORTANT:Suspendtheheaterfromthethreaded
nutretainers.Donotsuspendfromtheheatercabinet
panels.Donotplaceoraddadditionalweighttothe
suspendedairheater.Seehazardlevels,page2.The
heatermustbeinstalledinalevelplanetoensure
properoperation.
Figure3Suspensiondetail
Addanuttolockthe
M10x1.5hangerrod
totheheater



4.3FittingtheCombustionairinlet/Fluesystem

Fluepiperunsmaybehorizontalorverticalandterminateeitherthroughthewallorroof.Seetable5for
maximumpipelengthforanapplianceinstalledastypeBortable6formaximumlengthsandapproved
suppliedconcentricterminalsforaheaterinstalledasatypeCappliance.Allpiperunsmustbe
independentlysupportedsothattheheaterdoesnotcarryanyoftheweightofthefluesystem.

4.3.1Fittingthefluepipe(table5)
Thefluepipesocketislocatedonthebackoftheairheater.Fluepipesmustbesealed.Useseamless,aluminiumpipeor
equivalent.Followpipemanufacturer'sinstructions(seefigures4&5).

4.3.2Installingaguardonthecombustionairinletpipeforpowervent(TypeBinstallations)
Thecombustionairinletsocketislocatedatthebackoftheheater.WheninstalledasatypeBappliance,
protecttheinletbyfittinganaccessguardonthesocket.Donotblockthissocketasitsuppliescombustion
airfortheburner(seefigure4).

4.3.3Fittingthecombustionairinletpipeforbalancedflue(TypeCinstallations)(table6)
Thecombustionairpipeattachesdirectlytotheinletsocketatthebackoftheheater.Airinletpipesmust
besealed.Useseamlessaluminiumorequivalent.Followthepipemanufacturer'sinstallationinstructions.
Seetypicalinstallationsinfigure5.





4

1610VRA4‐AMEN,p10/24

Figure4 Figure5



4.4Gasconnection


Donotusetheappliancegassupplyto
balanceorsupportanypartofthe
appliance.

 Figure6

Connectiontoagasnetworkmayonlybecarriedoutby
appropriatelyqualifiedpersons.Thegasinstallationmust
complywiththerulesinforceusingmaterialsappropriatefor
gasinstallation.

Tofacilitateservicing,theairheatermustbefittedwithan
approvedgasservicetapandunionfittingoruniontap
adjacenttotheappliance.
Theinletgassupplylinemustbeinstalledsoastopermitthe
accessdoortobeopenedandtoallowremovaloftheslide
outburnerassembly.
Airheaterssuspendedbyflexiblesuspensionmaterialsordrop
rodsmustbeconnectedtothegassupplyusinganapproved
flexibleconnector.Sufficientslackmustbeprovidedinthe
connectiontoallowformovementoftheappliance.Usea
flexibleconnectorofsuitablesizetoreducethepressuredrop
andthepossibilityofgasflownoise.


4.5Electricalconnections


THISAPPLIANCEMUSTBEEARTHED!


IMPORTANT:Iftheresetbuttonrequiresactivatingfor
anyreasonthecauseshouldbeidentifiedbefore
resetting.Afterresettingstaywiththeapplianceforlong
enoughtoensurethatlock‐outdoesnotreoccur(suggest
5minutes).Fixallelectriccablesandinstaller’swiringto
thecontrolpanelandensuretheydonottouchthe
combustioncollectorbox.

Theelectricalinstallationmayonlybecarriedoutbyappropriatelyqualifiedpersonsobservingtherules
inforce.Allelectricalconnectionsshouldbemadeintheheatercontrolcompartment(refertofigure9).
Screwtypeterminalsareprovided.Connectionsshouldbeinaccordancewiththeterminalmarkingsand
thewiringdiagramaffixedtotheairheaterorincludedwiththisdocument.
Theminimumexternalcontrolsrequiredfortheairheaterarearoomthermostat.Itisessentialthemain
inputlineandneutraltoterminalsLandNremainsliveatalltimesevenwhentheapplianceis
switchedoffthisistoensurecorrectoperationoftheunit.

Anindicatorlightandburnerresetbuttonarefittedinsidetheappliance.Toaddaremoteresetbutton,
makeconnectionstotheterminalsintheelectricboxasindicatedonthewiringdiagram.
1Gastubeinletsealingring
2Inletgaspipe
3Unionfitting
4Gasservicetap
5Gas
p
i
p
e
danger

1610VRA4‐AMEN,p11/24
4.6Roomthermostatlocation

Donotattempttocontrolmorethan1airheaterfromaroomthermostatorcontrolpanelunlessa
properlywiredrelayisfitted.Followinstructionssuppliedwithsuchpanels.
Thelocationoftheroomthermostatisimportant.Itshouldnotbefittedonanoutsidewall.Avoid
locationindraughtyareasorwhereitmaybeinfluencedbyheatsourcese.g.thesun,processplant,etc.
Thethermostatortemperaturesensorshouldbemountedonavibrationfreesurfaceandmountedabout
1,5metresabovefloorlevel.Followthethermostatmanufacturersfittinginstructions.Thethermostat
mustbesuitableforswitching230volts.



  AIRDISTRIBUTION

VRA‐4airheatersarefittedwithadjustablehorizontallouversovertherange0‐45degreesfromthe
horizontalsoastobeabletodirecttheairflowdownwards.
DONOTADJUSTTHELOUVRESBEYONDTHEIRSTOPS.



  COMMISIONING&TESTING

Thecommissioningandtestingmayonlybecarriedoutbyappropriatelyqualifiedpersons.
Thissectionshouldbereadandfullyunderstoodbeforecommencingcommissioningandtesting.

6.1Electricalcheck

Aftercompletionoftheinstallationandbeforeswitchingontheelectricalsupplytotheappliance,a
preliminarycheckmustbecarriedoutbyaqualifiedelectrician.Thefollowingmustbechecked:

*Ensurethatallcables&installer’swiringarefixedtothegaspipe&thattheydonottouchthe
combustioncollectorbox
*Checkthatallwiringisconnectedinaccordancewiththeappliancecircuitdiagram;
*Ascertainthatthecorrectfusevalueandcablesizehasbeenprovided;
*Checktoensurethattheapplianceisearthedbyconductinganearthcontinuitytest.Connectatest
meter,oneleadtotheapplianceearthterminalandtheothertothemainsincomingearthpointat
theelectricalisolator.Aresistancereadingof1,0ohmorlessmustbeindicated.Ifahigherreading
isobtained,checkallcableconnectionstoensureadequatesecurityandcleanliness.Ifproblemstill
exists,itmaybenecessarytoconsulttheelectricitysupplyundertaking;
*Carryoutapolaritytest.ConnectoneleadofasuitableACvoltmetertoearthandconnecttheother
leadtothelivesupplyterminal(L)attheairheater.SwitchONthepowertotheairheaterandcheck
forcorrectvoltage.
Thesameresultshouldbeobtainedbyconnectingthetestleadsbetweenliveandneutral.
ConnectthevoltmetertestleadstoNandE.Areadingof0Vshouldbeobtained.Ifthesetestsdo
notconformtotheabove,thereisafaultwhichmustberectifiedbeforeproceedingfurtherwiththe
commissioning;
*Checkthatasuitablethermostatorcontrolpanelhasbeenfitted;
*Ensurethatanelectricalisolatorwithtwopoleseparationwithaminimumairbreakbetweenpoles
of3,0mmhasbeenfittedadjacenttotheairheater.

6.2Gasconnection

Onlypersonsformallyqualifiedtoworkongasfired
apparatusmaycarryoutcommissioningandtesting.
Thewholeofthegasserviceinstallationincludingthemetermustbeinspected,testedforsoundnessand
purgedinaccordancewithappropriaterequirementsbyaqualifiedperson.




5
6
Neveruseaflameforchecking
gassoundness.

1610VRA4‐AMEN,p12/24
Neveruseaflameforcheckinggas
soundness.
6.3Suspensionandsupport

Checktoensurethattheairheaterisadequatelysuspendedorsupportedandthatnootherpartshave
beenfittedthatarenotindependentlysupportedandsecured.Forsafeandcorrectoperation,checkthe
heaterislevelinbothplanes.


6.4Lightingtheairheater

VRA‐4airheatersareallfittedwithautomaticsparkignitionsystems.Whenadequateairflowfor
combustionisprovenbyanairprovingcontrolandapre‐purgeperiodhaselapsed,theintegralignitor
andmulti‐functionalgascontroloperate.Theignitionsparkignitesthegascreatingtheburnerflame
whichisdetectedbyaflamerodsensor.Ifaburnerflameisnotdetected,theignitioncontroller
proceedstolock‐outandrequiresmanuallyresetting.Lock‐outisindicatedbytheredwarninglighton
theairheater.Ifthefirstresetisnotsuccessful,wait15secondsbeforeattemptingreset.

6.4.1Toturntheairheater"ON"
Thefollowingchecksshouldbecarriedoutbeforeattemptingtolighttheairheater.
*EnsurethatthegassupplytotheairheateristurnedON;
*EnsurethattheelectricalsupplytotheairheaterisswitchedON;
*IffittedensurethatatimeswitchissettoanONperiod
*Setroomthermostattocallforheat.e.g.toaboveroomambienttemperature.Theburnerwillnowlight.
Theburnerscanbeseenthroughtheviewingport.
*Adjusttheroomthermostattotherequiredoperatingcomforttemperature.Theairheaterwillnow
startautomaticallywhenheatiscalledforbytheroomthermostat.
Note:Iftheairheaterwillnotstartoninitialstart‐up,theignitioncontrollermaybeinlock‐outpositionandrequire
resetting.Thismayoccurespeciallyiftheappliancehasbeenonstand‐byforaprolongedperiod.

6.4.2Toturntheairheater"OFF"forshortperiods
Adjusttheroomthermostattoitslowestsettingor'OFF'.Thefanwillcontinuetoruntocooltheheater
andthenswitchOFFautomatically.

6.4.3Toturntheairheater"OFF"forlongperiods
AdjusttheroomthermostattoOFForitslowestsetting.Whenthefanhasstopped,turnOFFthegas
supplyandthenswitchOFFtheelectricitysupplytotheairheater.


6.5Airheatergaspipework
Thesoundnessoftheairheaterpipeworkhasbeen
checkedpriortoleavingthefactory.Howeverduring
installation,connectionsmayhavebeenloosened.
Checkthesoundnessoftheappliancepipeworkusingasoapysolution.Ifanyleaksarefoundtheymust
berectifiedimmediately.


6.6Adjustments

6.6.1Burnergaspressureadjustment
Thegaspressureissetfortherequiredheatinputbeforetheapplianceleavesthefactory.Providedthe
gassupplytotheairheaterisinaccordancewiththesupplypressuredescribedontheappliancedata
platetheoperatingpressurewillnotrequireadjustment.Tocheckthepressure,thefollowingprocedure
shouldbecarriedout:
* Ascertainfromsection1ofthisdocumentandtheappliancedataplatethecorrectoperatinggas
pressurefortheairheater;
* Turntheroomthermostatcontroltoitslowestsetting;
* Removethescrewfromtheburnerpressuretestpointofthemulti‐functionalcontrolvalve.Connecta
manometertothetestpoint(seefigure7);
* Adjusttheroomthermostattocallforheate.g.aboveroomambienttemperature;
* Observetheburnergaspressureonthemanometerandcomparetotherequiredpressure;
* Ifnecessary,adjusttheburnergaspressure(onlyfornaturalgas).Removethecoverscrew.Turnthe
regulatorscrewanti‐clockwisetodecreasepressureorclockwisetoincreasepressure(seefigure7);
* SetroomthermostattolowestsettingtoturntheburnersOFF.Replacethetestpointscrew(if
removed)andwiththemainburneralight,testforgassoundnessusingasoapysolution.
Resettemperaturecontrol/roomthermostattocomfortoperatinglevel.

1610VRA4‐AMEN,p13/24


Figure7:Honeywellgasvalve






1GasvalveHONEYWELLVR4601AB
2Inletpressuregastestpoint
3Burnerpressuregastestpoint
4Burnerpressureregulatorcover
5Burnerpressureregulator
6Electricalconnection230V


6.7Airdistributionsystem

Adjusttheairoutletdischargelouverstoprovidea
satisfactoryspreadofthewarmair.Directtheair
towardstheflooravoidingblowingdirectlyon
peoplewhomaybeinthevicinityoftheappliance.
Iflouver adjustmentiscarriedoutwhilst
theapplianceishotwearglovestoavoid
beingburnt.



6.8Airheatercontrolsandoperation

Checkairheateroperationafteralladjustmentshave
beencarriedout.Setthetemperaturecontrolabove
ambienttemperature.
VRA‐4airheatersarefittedwithapressuresensitive,
combustionairsafetycontrolthatmonitorsthe
combustionairflow.Thecontroloperateswiththe
settingsgivenintable10(settingsareforsealevel
installations)
Whenthecombustionairsafetycontrolcloses,verifying
airflow,thegascontrolvalvewillopenandtheburner
willlight.Wheninsufficientairflow,theburnerwill
extinguishuntiltheairflowreturnstotheacceptable
level.Waitapproximately30secondsaftertheburner
haslit,thetimedelayrelaywillactivatethethermalfan
controlwhichwillenergizethefanmotor.

Table7 Combustionairpressurecontrolsettings
At2x1mpipewithterminal

Continuetooperatetheairheaterforseveralminutestoensurecorrectoperation.Turnroomthermostat
toitslowestsetting.Themainburnersshouldextinguishwhilethefancontinuestoruntocooltheair
heater.Thefandelayrelaywillnormallybede‐energizedandstopthefanmotorinapproximately45
seconds.


6.9Handingover

Uponsatisfactorycompletionofcommissioningandtesting,handtheinstructionstotheuserortheir
representative.
Advisetheappropriatepersonhowtosafelyuseandoperatetheairheateranddescribetheuseof
appropriateexternalcontrols.Ensurethatthepersonunderstandshowtostarttheheaterandhowto
turnitOFF.
Suggestthattheinstructionsareplacedclosetotheairheaterforfuturereference.Intheabsenceofan
appropriatelocationfixthemtothegasservicemeter.Ensuretheyarenotplacedwheretheymay
restricttheairflowfromtheheaterorwheretheymaycatchfirefromahotsurface.Advisetheperson
whoisresumingresponsibilitythatforcontinuedsafeoperationtheairheatershouldbeservicedatleast
onceayear.

VRA-4 Normal equilibrium
warm (Pascal)
Set point
'off'
(Pascal)
12 >131 119
20 >163 135
30 >170 130
35 >200 155
45/50 >183 155
60 >240 175
75 >290 185
100 >250 210
120 >250 238
145 >250 238

1610VRA4‐AMEN,p14/24
SERVICINGINSTRUCTIONS

IMPORTANT:Onlyappropriatelyqualifiedpersonsmaycarryoutservicingandfaultfindingonthisgasfiredequipment.
Beforecommencingserviceensurethatboththegasandtheelectricityareturnedandswitched"OFF"andthattheair
heaterhascooleddown.Inadvertentsubstitutionorreplacementofcomponentssimilartothosespecifiedor
replacementinamannercontrarytothemethodhereindescribedcouldconstituteahazardandleadtoprosecution.
VRA‐4airheaterswilloperatewithaminimumofmaintenance.Toensurelonglifeandsatisfactoryand
safeperformance,anairheaterthatisoperatedundernormalconditionsshouldbeinspectedand
cleanedatthestartofeachheatingseason.Iftheairheaterisoperatedinanareawhereunusual
amountsofdust,etcarepresentintheair,morefrequentservicingisrecommended.
Whenanyserviceiscompleted,besurethatcomponentsarereassembledcorrectlytoensurethatno
unsafeconditionexists.
Uponcompletionoftheservicecarryoutthecommissioninginstructionsoutlinedinsection6ofthis
document.


Whencleaningairheaters,
wearingofeyeprotection
andadustfacemaskis
recommended.



WARNING:Excessivedirtbuild‐upontheinsideofthe
burnerportscouldcauseunburntgastospilloutofthe
backoftheburnertubecausingafireorexplosion.To
preventthisoccurring,cleanalloftheburnerportsat
leastannually.

Serviceprocedure

Thefollowingproceduresshouldbecarriedoutatleastannually:
1.Removetheburnerassemblyasinsection8.1.Cleanthoroughly,(cleaningtheburnersrequiresan
emerycloth,wirebrushandacleaningcloth‐stubborndepositsonburnersarebestcleanedusing
"acetone"asasolvent).
*Checktheconditionoftheignitorandcleantoremovealldeposits.Checkthesparkgap(3,0mm).
*Checkthesensor‐cleanasnecessary.
*Removeanysootdepositsfromtheburnerwithawirebrush.Cleantheportswithadegreaseror
acetone.Avacuumcleanerorcompressedairmayassistinthiscleaningoperation.Wipetheinside
oftheburnertubeclean(cleaningthoroughlywithadegreaserasrecommendedwillretardfuture
build‐upofdirt).Inspecttheburnerforanydamageordeterioration.Iftheburnerisdamagedor
corroded,replaceit.
2.Theheatexchangershouldremaincleanunlessaproblemhasdevelopedduetopoorcombustion.
Examinetheheatexchangertubesinternallyandexternallyforanysignofdeterioration.Theoutside
ofthetubularheatexchangercanbecleanedfromthefrontoftheheaterwithanairjetand/ora
flexiblebrush.Removeanydustandgreasedeposits.
Theinnersurfacesoftheheatexchangercanbereachedforcleaningwiththeburnerandcombustion
airfan(venter)assembliesremoved.Cleanwithafluebrushoraheavywiretowhichwirewoolhas
beenattached.
Brushinsideeachheatexchangertubeuntilallforeignmaterialhasbeenremoved.Theuseofa
flashlightisnecessarytocarryoutthisoperation.
3.Cleantheaxialfanblades,fanguard,andfanmotortoremoveallexternaldirt.Checkthesecurityof
thefanonthemotor.
Note:Fanmotorsarelubricatedforlifeanddonotrequirelubricating.
4.Removeanydirtand/orgreasethatmayhaveaccumulatedontheventerfanmotoranditshousing.
Note:Thecombustionairfanmotorsarelubricatedforlifeanddonotrequireoilingorgreasing.
5.Thegasmulti‐functionalcontrolvalverequiresnofieldmaintenanceexceptcleaningofitsexterior
andcheckingtheconditionofthewireconnections.Instructionsfortestingpressurearegivenin
section6.6.
6.Checktheflue/combustionairsystemforsoundness.Reseal/replaceanypartsthatarenotsound.
7. Checkallwiringconnections.Checkwiringforanysignsofdamage.Replaceanysuspectwiringwithan
equivalentspecification.
8.Checkoperationofthermalfancontrolandcontrolrelay.
9.Whenserviceiscompletecarryoutfullcommissioningprocedureaspersection6ofthisdocument.


7

1610VRA4‐AMEN,p15/24
 Removal&replacementofparts
VRA‐4airheatersmustonlybefittedwithauthorizedreplacementparts.Theseheatersmustuse
certificatedsparepartstocomplywithlegislation.

Remember!Afteranyserviceworkhasbeencarriedout,theairheatermustbefullycommissioned.
 Seesection6ofthisdocument

8.1Mainburnerremoval

Instructionsforburnerremoval(seefigure8):
1.TurnOFFthegassupplytotheairheater.
2.SwitchOFFtheelectricitysupplytotheairheater.
3.Opentheaccessdoor.
4.Disconnecttheunioninthegassupplyoutsideoftheappliance.
5.Removegassupplypipefrommulti‐functionalgascontrolvalve.
6.Attheburnerrackassembly,removethenutsthatsecuretheburner
manifoldtotheburnerrack.Lifttheburnerrack/manifoldassembly
upwardandpulltheassemblyoutoftheairheater.
Instructionsforre‐assembly:
1.Reversetheprocedureforremovalmakingsurethatallpartsareinstalled
correctly.Checkthatallcomponentsaresecure.
2Whenlighting,alwaysfollowthelightinginstructionsontheairheater.



Figure9ViewoftheControlCompartment






8.2Burnerinjectors

1.Carryoutsteps1to6ofsection8.1.
2.Unscrewthemainburnerinjectors.
3.Re‐fitnewinjectors.
4.Re‐assembleinreverseorder.

1
2
3
4
5
6
7
8
9
10
11
12
14
13 1 Burner
2 LC3 limit controls
3 Burner operating lamp H6
4 Reset switch S3
5 Spark igniter ER
6 Control panel
7 Gas valve V1
8 Fan motor M1
9 Venter motor M3
10 Fan control relay KFC
11 LC1 limit control
12 Flame sensor IS
13 Reset LC3
14 Fuse F3.1
8
Figure8(forclarity,heater
cabinet&otherpartsarenot
illustrated

1610VRA4‐AMEN,p16/24
Duetohighvoltageonthesparkwire
andelectrode,donottouchwhen
ener
g
ized.Seehazardlevels.

8.3Ignitionsystem
Toaccesstheignitionsystem,followsteps1to3in§8.1.
Ignitor‐refertofigure9andlocatetheignitor(onthesideof
theburnerrack).Disconnectthewire,removethescrewandthe
ignitor.Cleanwithanemerycloth.
Note:Sparkgapmustbemaintainedto3.0mm(seefigure10a).Re‐fittheignitorasperfigure10b.
Flamesensor‐Refertofigure9andlocatetheflamesensor.Disconnectthewire,removethescrewandtheflame
sensor.Cleanwithanemerycloth.
Ignitioncontroller‐Theenclosedintegratedcircuitmonitorstheoperationoftheburnerincludingignition.Donot
attempttodismantletheignitioncontroller.Eachheatingseasonignitioncablesshouldbecheckedforinsulation
deteriorationandgoodconnections.
Properoperationofthedirectsparkignitionsystemrequiresaminimumflamecurrentof1,0μAwhenmeasured
withamicro‐ammeter.

Fig.10a‐Ignitorassembl
y


Forfurtherinformationandcheckoutprocedureofthedirect
sparkignitionsystem,refertothemanufacturerscontrol
operatinginstructionsacopyofwhichissuppliedwiththeair
heater.
Fig.10b ‐:Fittingtheignitor


8.4Multi‐functionalgascontrolvalve
1.EnsuregassupplytotheairheateristurnedOFF.
2.Aftertheaircirculationfanhasstopped,switchOFFtheelectricitysupplytotheairheater.
3.Markforfutureidentificationanddisconnectthewiresconnectedtothevalve.
4.Disconnectthegasserviceunionbetweenthecontrolvalveandthegasservicetap.Removethegascontrolvalve.
5.Re‐fitareplacementvalvemakingalloftherequiredconnections.
6Carryoutcompletecommissioningprocedurepriortoplacingtheappliancebackintoserviceasoutlinedin
section6.0


Thegascontroloperatingvalveistheprimesafetyshut‐off.Allgassupplylinesmustbefreeofdirt,scale,
etc.beforeconnectingtotheairheaterthusensuringpositiveclosureofthecontrolvalve.

8.5Thermaloverheat(limit)controls
Ifitisdeterminedthatthethermaloverheatcontrolneedsreplacing,useonlyauthorizedreplacementsthatare
designedforthisappliance.Togainaccesstothecontrol,openthecontrolscompartmentaccessdoor.Refertofigure
9forcontrollocations.Thecontrolnearthetopoftheairheaterisadisctypecontrol.Bothcontrolsarecapillary
typeswithacapillarytubethatextendsintotheheatexchangerarea.Toremovethecontrols,disconnectthewires
leadingtothem,removethefixingscrewsandliftclearoftheinnercasingpanel.Whenreplacingacapillarycontrolbe
carefulnottodamagethecapillarytubebykinking.Makebendswithagenerousradius(approx25mm).Note:The
capillarycontrolisfittedtoabracket.Withthebracketremovedfromtheheater,removethecontrolfromthe
bracket.

8.6Combustionaircontrol/switch
Ifitisdeterminedthattheairdifferentialpressureswitchneedsreplacing,useonlyauthorizedreplacementsthatare
designedfortheairheaterbeingserviced.Theseswitchesarecalibratedtooperateatthedesignedcombustionair
flowdutyforeachappliancesizeintheproductrange.

8.7Combustionairfan(venter)(Thecombustionairfanmotorislubricatedforlife.Donotoilorgrease.)
1.EnsuregassupplytotheairheateristurnedOFF
2.Aftertheaircirculationfanhasstopped,switchOFFtheelectricitysupplytotheairheater.
3.Togainaccesstothefanopenthehingedcontrolscompartmentaccessdoor.Refertofigure9forlocation
4.Markforfutureidentificationanddisconnectthewiresconnectingthefanmotorattheterminalsonthemain
wiringjunction.
5.Removecombustionairfanandcleanasnecessaryusingawirebrushandsolventtoremovestickyresidues.
6.Re‐assembleandcheckforfreerotationbeforeproceedingtotesttheappliance.

1610VRA4‐AMEN,p17/24

  FAULTFINDING
Faultfindingmayonlybecarriedoutbyappropriatelyqualifiedpersons


9.1Mainfaultfindingchart‐Lock‐outindicatorlightis"OFF",butairheaterwillnotoperate

no
yes
yes
no
no yes
yes
no
no
yes no yes
no
yes
yes
no
no yes
no
yes
yes
Is there continuity between
terminals 9 &10
Check electronic
ignition control
Is there a restriction in the
flue pipe or inlet grill
Is the wheel dirty
Determine what caused the
limit totrip
Place into normal operation
Check the mains
Check the time/tempeature
control
Is there continuity between
9 & 10 ?
Is there 230V between
11 & 12 ?
Is power venting operating?
Reset limit control
Check venter motor
Replace pressure switch
Is the thermostat above
roomtemperature and if
usedisthetime
clock"ON" Set thermostat above room
temperature & if used make
certainthetimeclock isON
Does the power venter
operate?
Is there 230V between
L&N?
Is there 230V between
1 & N ?
Check pressure switch
Connect or replace tubing
Correct fault
Is the pressure tubing
connected &in sound
condition?
Clean the venter wheel

9

1610VRA4‐AMEN,p18/24
9.2IgnitionControllerLockoutindicatorLightRepeatedlyComes"ON"


no
yes
no yes
no no
yes
no yes
yes
no
yes
no
yes
check
electronic
ignition
control
Place in normal
operation
check multi
functional
gas valve
Spark visible, still no
flame
Is there 220 to 240V
between terminals
13 & N
Check electronic
ignition control
correct the gas supply
pressure
During 5" trial for ignition
is a spark visible?
Check electronic
ignition control
Check spark gap and
ceramic & check
spark wire &
connector Is a spark visible ?
Check flame signal. Is it
greater than 1,0 micro
Amps?
Check flame signal using
micro amp meter. Is signal
greater than 1,0 micro
Amps?
During 5" trial for ignition is
a flame visible in ths view
port?
Correct polarity
Does the inlet gas
pressure agree with the
data badge
Is polarity of mains
correct?
Remove corrosion
& scale from flame
sensing rod & clean
ceramic insulation
Wait 15" and press
reset button





1610VRA4‐AMEN,p19/24
9.3LimitControlFaultFindingChart(limitcontroltrips)

NoteVRA‐4airheatersareequippedwith2limits(arecyclinglimitandamanualresetlimit).Duringnormaloperation,
neitherlimitshouldtripevenifthemainelectricsupplyisinterruptedduringoperation.Intheeventofmotorfailure,the
recyclinglimitwilltripopeningthegasvalve.


yes
no yes
yes no
yes
no no
yes
yes
no
Check for excessive
main burner pressure
Does the fan
motor operate?
Remove the
restricition
Has any non-factory authorized air distribution
device been placed on the heater? Is there excessive
static pressure in the ductwork? Did the motor overload
trip?
Does the fan control
energize the fan motor
in less than 75"?
Adjust thermostat
temp. setting above
ambient to energize fan
& gas solenoid valve
Replace
the motor
Consult fan
fault finding
Does the limit trip
before the fan is
energized?
Place system in normal
operation
Consult fan
fault finding
Is there 220-240V at
terminals N and 4?

9.4FanFaultFindingChart



no no yes
yes
Adjust thermostat
temperature
setting above ambient to
energize the fan and the
fan solenoid valve
Does the fan
operate ?
Is there 220-240V
at terminals N & 4?
Replace the
fan start relay Replace fan
motor
Place the system in
normal operation



1610VRA4‐AMEN,p20/24
  PARTSLISTING


VRA-4 Part number
Delta P switch S3: 12 30 60617 238 238Pa out 250Pa in
Delta P switch S3: 20/30 30 60617 175 175Pa out 203Pa in
Delta P switch S3: 35/45 30 60621 155 1627Pa out 1767Pa in
Delta P switch S3: 50 30 60617 200 200Pa out 210Pa in
Delta P switch S3: 60 / 75 / 100 30 60617 175 175Pa out 203Pa in
Delta P switch S3: 120/145 30 60617 185 185Pa out 203Pa in
Overheat control device LC1 (not 120/145) 03 24959 04 90°C out 85° C in
Overheat control device LC3 (all, exc 100, 120 & 145) 03 24959 03 110° C out reset
Overheat control device LC3 (100) 03 24959 96° C out reset
Overheat control device LC3 (120/145) 03 24959 03 110° C out reset
Overheat control device LC3 (120/145) 03 24958 86° C out reset
Venter motor (all exc 120/145) 11 43426 04
Venter motor 120/145 20 25749
Gas valve one stage 35/45/60/75/100 03 25136
Gas valve one stage 12/20/30 03 25141
Gas valve one stage 120/145 03 25144
Burner relay E 03 25324
Ignition electrode ER 03 400US 42
Ignition electrode ER (120/145) 05 25186
Flame sensor electrode IS 03 401US 195292
ERP fan 12 01 27003
ERP fan 20 01 27006
ERP fan 30 01 27021
ERP fan 35/45 01 27010 01
ERP fan 50 01 27011 01
ERP fan 60/75 01 26063
ERP fan 100 01 27014 02
ERP fan 120/145 (2x) 01 26063
Settings




  GASCONVERSION

VRA‐4airheatersaredesignedtooperateonnaturalorpropanegasandwillbesuppliedfittedfor
thegastypeordered.Intheeventofsiteconversiontoadifferentgastypeitisnecessarytoconvert
thegasburnerandburnercontrols.
Affixnewdataplateandgastypeover‐sticker.
Uponcompletionofconversionre‐commissiontheairheaterinaccordancewithsection6ofthis
document.
Changestocarryout:
-Naturalgas:useHoneywellVR4601AB(PN0325136)‐setpressureregulatorasperTable2A
‐Propane:useHoneywellVR4601B (PN0325136B)orVR4601AB+blockingplate

Toadaptgasinjectorsandgasinletpressures,werefertotable2A/2B.
10
11