Nortek Reznor VRA20-4E Guide
1712VRA‐4EGBEN,pag.1/25
1712VRA-4EGBEN
MODULATING,GAS‐FIRED,BALANCEDFLUEOR
POWER‐VENTEDUNITHEATER
VRA‐4E
INSTALLATION
COMMISSIONING
SERVICING
ThisappliancemeetsthefollowingECDirectives
DIR2009/142/EC:GAD
DIR2014/30/EC:EMC
DIR2014/35/EC:LVD
DIR2006/42/EC:MD
Pleasereadthisdocumentcarefullybeforecommencinginstallationcommissioningand/orservicing.Leaveitwiththeuser
orattachedtotheapplianceorgasservicemeterafterinstallation.
WARNING
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,injuryordeath.Allwork
mustbecarriedoutbyappropriatelyqualifiedpersons.Themanufacturerdoesnottakeanyresponsibilityintheeventof
non‐observanceoftheregulationconcerningtheconnectionoftheapparatuscausingaharmfuloperationpossiblyresulting
indamagetotheapparatusand/orenvironmentinwhichtheunitisinstalled.
Subjecttomodifications
1712VRA‐4EGBEN,pag..2/25
TABLEOFCONTENTS
1.0INTRODUCTION p3
1.1 BasicInformation
1.2 Warranty
2.0TECHNICALDATA p4
2.1 Specifications
2.2 Dimensions
3.0GENERALREQUIREMENTS p5
3.1 RelatedDocuments
3.2 HeaterLocation
3.3 CombustionAirInletPipeandFluePipe
3.4 AirSupply
3.5 AirDistributionSystem
3.6 ElectricalSupply
3.7 GasSupply
4.0INSTALLATION p9
4.1 UncratingandPreparation
4.2 SuspendingtheHeater
4.3 FittingtheCombustionAirInlet/FluePipe
System
4.4 GasConnection
4.5 ElectricalConnections
4.6 RoomThermostatSiting
5.0AIRDISTRIBUTION p10
6.0COMMISSIONINGANDTESTING
p11
6.1 ElectricalCheck
6.2 GasConnection
6.3 SuspensionandSupport
6.4 LightingtheHeater
6.5 Heaterpipework
6.6 Adjustments
6.7 AirDistributionSystem
6.8 HeaterControls
6.9 HandingOver
7.0SERVICINGINSTRUCTIONS p14
8.0REMOVALANDREPLACEMENTOFPARTSp15
8.1 MainBurnerRemoval
8.2 MainBurnerInjectors
8.3 IgnitionSystem
8.4 OperatingGasValve
8.5 LimitControls
8.6 CombustionAirPressureSwitch
8.7CombustionAirFan
9.0FAULTFINDING p17
10.0PARTSLIST p20
11.0GASCONVERSION p20
12.0USERSINSTRUCTIONS
p21
13.0HEALTH&SAFETYSTATEMENT
p22
HAZARDINTENSITYLEVELS
DANGER
Failuretocomplywill resultinseverepersonalinjuryordeathand/or
propertydamage.
WARNING
Failuretocomplycould resultinseverepersonalinjuryordeathand/or
propertydamage.
CAUTION
Failuretocomplycouldresultinminorpersonalinjuryand/orproperty
damage.
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.
1712VRA‐4EGBEN,pag..3/25
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-4E 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
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:
a) VRA-4E 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.
1
WARNINGS
1712VRA‐4EGBEN,pag..4/25
VRA-4E 12 20 30 35 45 50 60 75 100 120 145
Quantity 5568108810121012
mm1,52,12,12,22,22,42,72,72,93,43,4
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 s ize
TECHNICAL DATA
2.1 Specifications
Table1
VRA-4E 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 3031 333331303429293235
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 2,53 444455566
Horizontal throw
(5)
m 9,5 13 17 24 25 27 30 32 31 38 39
Sound Pressure
(6)
dB(A)3642 374645454748525456
Sound Pressure
(7)
dB(A)4349 445352525455596163
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
Table2:InjectorsizeandburnerpressureG20naturalgas(Inletpressure=20.0mbar)
Table2:InjectorsizeandburnerpressureG20naturalgas(Inletpressure=20mbar)
Table3:InjectorsizeandburnerpressureG30/G31butane/propane(InletpressureG30=28mbar‐G31=37mbar)
V
RA-4E 1220303545506075100120145
Quantity 5 6 8 10 8 8 10 12 10 12
mm 1,15 1,15 1,15 1,15 1,4 1,5 1,45 1,5 1,95 1,9
marking 115 115 115 115 140 150 145 150 195 190
butane N.A. 28,1 28,1 28,4 28,14 27,9 27,75 26,96
propane 34,20 34,40 36,20 35,90 30,10 35,20 35,40 34,40 30,70 30,60
Injector size
Burner pressure (mbar) (1)
1) with open service door
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
=
160m
²
and Q
=
2
1712VRA‐4EGBEN,pag..5/25
K
L
S
R
N
M
P
Q
D
Flue Outlet
D
Flue Inlet
W
Gas Connection
1
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-4E A B C D E F G H I J K L M N P Q R S T U V W
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
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.
1 Electrical connections
2 Service panel
3 Suspension points (M10 female)
Figure1
3
1712VRA‐4EGBEN,pag..6/25
Table 4 Min. installation clearances
VRA-4E 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
Table 5 Recommended mounting heights (m) (*)
VRA-4E 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.
3.3.1 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 6 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.
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.
1712VRA‐4EGBEN,pag..7/25
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 requirements
12 20‐30 35‐145
mm Fluepipe/Inletpipe 80 100 130
mFluepipe/Inletpipe999
mFluepipe/Inletpipe 0,75 0,75 0,75
mFluepipe/Inletpipe 1,5 1,5 1,5
mFluepipe/Inletpipe 2,5 2,5 nvtEquivalentLengthof
90°elbow
VRA‐4E
Heatersocket&pipedia
Maxstraightlength
Equivalentlengthof45°
elbow
Equivalentlengthof90°
elbow
Concentric vertical vent or wall terminal : Mugro/Burfix dia 130
Concentric horizontal vent or roof terminal : Mugro/Burfix dia 130
1712VRA‐4EGBEN,pag..8/25
3.4 Air supply 3.5 Air distribution
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)
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
Wiringexternaltotheairheatermustbe
carriedoutinaccordancewiththerulesinforce
andbyappropriately 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-4E 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.
1712VRA‐4EGBEN,pag..9/25
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.
Figure 4
Figure 5
4
1712VRA‐4EGBEN,pag..10/25
4.4 Gas connection 4.5 Electrical connections
Do not use the appliance gas
supply to balance or support
any part of the appliance.
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.
Figure 6
AIR DISTRIBUTION
VRA-4E 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.
1Gastubeinletsealingring
2Inletgaspipe
3Unionfitting
4Gasservicetap
5Gas
p
i
p
e
4.5 Electrical connection
ATTENTION
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.
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.
5
1712VRA‐4EGBEN,pag..11/25
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
ATTENTION :
NEVER USE A FLAME FOR CHECKING GAS
SOUNDNESS!
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.
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
1712VRA‐4EGBEN,pag..12/25
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
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.
Figure 7a : Gas valve types 20-30 Figure 7b : Gas valve types 35-145
1) Shut-off solenoid valve EV1
2a) Adjustment low fire
2b) Adjustment high fire
3) Inlet pressure test point (not visible on fig. 7b)
4) Outlet pressure test point (not visible on fig7b)
5) Shut-off solenoid valve EV2
6) Pilot outlet
7) Main gas outlet
8) Holes (M5) for fixing flanges
1712VRA‐4EGBEN,pag..13/25
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.
ATTENTION :
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-4E air heaters are fitted with a pressure
sensitive, combustion air safety control that monitors
the combustion airflow. The control operates with the
settings as specified in the parts list (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.
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.
1712VRA‐4EGBEN,pag..14/25
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-4E 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.
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.
CAUTION : When cleaning air heaters, wearing of eye
protection and a dust face mask is recommended.
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
1712VRA‐4EGBEN,pag..15/25
Removal & replacement of parts
VRA-4E 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.
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
Figure 8
Figure 9 View of the Control Compartment
8
1) Burner 7) Main gas valve (V1)
2) LC3 limit control 8) Venter motor
3) Burner operating LED 9) Limit control LC1
4) Reset switch+burner lockout 10) Flame sensor (IS)
5) Spark ignitor (ER) 11) Modulating gas valve (VM)
6) Control panel
1712VRA‐4EGBEN,pag..16/25
8.3 Ignition system
To access the ignition system, follow steps 1 to 3 in
§ 8.1.
ATTENTION : Due to high voltage on the spark
wire and electrode, do not touch when energized.
See hazard levels.
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 assembly
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.
ATTENTION : 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 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.
8.6 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.
8.7 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.
1712VRA‐4EGBEN,pag..17/25
FAULT FINDING
Fault finding may only be carried out by appropriately qualified persons
Airheaterdoesnotoperateandlock‐outindicatorlightisoff
Airheaterdoesnotoperateandlock‐outindicatorlightison
9
1712VRA‐4EGBEN,pag..18/25
1712VRA‐4EGBEN,pag..19/25
1712VRA‐4EGBEN,pag..20/25
PARTS LISTING
VRA-4 E Part number
Delta P switch S3: 12 30 606177 200 238Pa out 250Pa in
Delta P switch S3: 20 30 60617 185 175Pa out 203Pa in
Delta P switch S3: 30/35/45/50/60/75 30 60621 175 1627Pa out 1767Pa in
Delta P switch S3: 120/145 30 60617 185 185Pa out 203Pa in
Delta P switch S3 : 100 30 60621 130 135±5Pa out 147±5Pa 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 modureg 35/45/60/75/100 03 25136M
Gas valve modureg 12/20/30 03 25141M
Gas valve modureg 120/145M 03 25144M
Burner relay E 03 25321
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-4E 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
This manual suits for next models
11
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