Cumberland VariFlame VF-16-ONG Owner'S Manual Download Page 7

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Chapter 1: Safety Precautions

Safety Precautions

Use Personal Protective Equipment

• Use appropriate personal protective equipment:

Eye
Protection

Respiratory
Protection

Foot
Protection

Hearing
Protection

Head
Protection

Fall
Protection

Hand
Protection

• Wear clothing appropriate to the job.

• Remove all jewelry.

• Tie long hair up and back.

ST-0004–1

PNEG-2091

VariFlame™ Heater

Summary of Contents for VariFlame VF-16-ONG

Page 1: ...VariFlame Heater Patent Pending Models VF 16 OPS VF 16 OPP VF 16 OPG VF 16 ONS VF 16 ONP VF 16 ONG Owner s Manual PNEG 2091 Version 04 Date 02 01 19 PNEG 2091...

Page 2: ...be filled out and kept on record Equipment Information Model Number Serial Number Date Purchased Dealer Name and Phone Number All information illustrations photos and specifications in this manual ar...

Page 3: ...Startup and Operation 35 Pre startup inspections 35 Emergency heater shutdown 35 Normal heater shutdown 35 Starting the heater 36 Operating the burner 36 Adjusting the heater output 37 Chapter 6 Servi...

Page 4: ...NOTES 4 PNEG 2091 VariFlame Heater...

Page 5: ...others as required Unqualified persons must stay out of the work area at all times Alterations must not be made to the equipment Alterations can produce dangerous situations resulting in SERIOUS INJU...

Page 6: ...his symbol indicates an imminently hazardous situation which if not avoided will result in serious injury or death This symbol indicates a potentially hazardous situation which if not avoided can resu...

Page 7: ...appropriate personal protective equipment Eye Protection Respiratory Protection Foot Protection Hearing Protection Head Protection Fall Protection Hand Protection Wear clothing appropriate to the job...

Page 8: ...not understand any part of this manual or need assistance contact your dealer Retain these instructions for future reference ST 0025 3 For Your Safety If you smell gas 1 Open windows 2 Don t touch ele...

Page 9: ...rol and may start without warning Do not service the heater without first disconnecting and locking out power Keep area clean and dry Keep hands feet and clothing away from moving parts Keep the heate...

Page 10: ...rovincial regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made For the United States The equipment shall be ins...

Page 11: ...by a qualified electrician Lock out power source before making adjustments cleaning or maintaining equipment ST 0069 1 Improper Use Warning The intended use of this appliance is the heating of agricul...

Page 12: ...od by all personnel involved in the installation operation service and maintenance of the equipment Location Decal No Decal Description Inside door panel DC 2425 Warning Electrical Hazard Instructions...

Page 13: ...29 Caution On Door DC 2430 Warning Hot Surface Over Heater Outlet Cover DC 2457 Warning Fire Hazard To replace a damaged or missing decal contact us to receive a free replacement GSI Decals 1004 E Ill...

Page 14: ...ign off sheet that can be used to verify that all personnel have read and understood the safety instructions This sign off sheet is provided for your convenience and personal record keeping Date Emplo...

Page 15: ...in W C Inlet gas supply pressure minimum 12 0 in W C Burner manifold pressure maximum 10 0 in W C Burner manifold pressure minimum 0 4 in W C Fuel consumption per hour maximum 11 58 lbs Fuel consumpt...

Page 16: ...18 6 x 27 5 Net weight 98 lbs Shipping weight 112 lbs Minimum combustion distance Top 1 ft 0 3 m Sides 1 ft 0 3 m Back 1 ft 0 3 m Blower outlet 6 ft 1 83 m Electrical and environmental specifications...

Page 17: ...hold and similar use Part 2 5 Particular requirements for automatic electrical burner control systems IEC 60730 2 5 2000 A1 2004 A2 2008 MOD It is an Installation Category III intended for operation f...

Page 18: ...energize the fuel flow means if proof of the supervised burner flame is not established In the USA this period is referred to as the trial for ignition period ms 3870 4300 4730 The period of time betw...

Page 19: ...ng Switch 4 Igniter 5 Flame Probe 6 Control Board 7 Throttle Valve 8 Gas Valve Blower motor and wheel assembly 1 The blower motor and wheel assembly provides all of the airflow in the heater It is imp...

Page 20: ...s is turned on by the heater When the igniter is operating properly it should glow red when power is supplied to it Typical sources of igniter failure include improper handling improper maintenance an...

Page 21: ...Chapter 3 System Overview Burner control module and sequence of operation Figure 3 2 VariFlame Sequence of Operation PNEG 2091 VariFlame Heater 21...

Page 22: ...it verifies the stability of the flame for 6 seconds If the flame is stable the burner is considered on If at anytime during this process the gas valve is not found to be energized or the flame is un...

Page 23: ...Air diverters are shipped flat and can be bent to direct the heated air as it exits the heater 1 Bend the diverter flaps 1 to the desired angle 2 Bend the top and bottom sides down making sure the ta...

Page 24: ...try applications and mini mum of 48 in from the ground in hog confinement Make sure that the bottom air intake is not restricted in any manner What You Should Know 1 Install the j hooks with the lock...

Page 25: ...nto service 8 Install a sediment trap and a manual shut off valve to the heater s gas inlet 9 Install a low pressure gauge tester to the gas valve to verify that the gas pressure is within the range s...

Page 26: ...n Figure 4 4 Gas and Electrical Connections 1 Sediment trap 2 Electrical cord 3 Electrical outlet 4 Vent to outside 5 Gas hose 6 Gas pipe 7 Regulator 8 Shut Off valve 9 Heater 10 Air diverter 26 PNEG...

Page 27: ...agrams and schematics to connect components to the VariFlame Edge controller DANGER Make sure all power sources are disconnected and locked out before performing any maintenance to the equipment Figur...

Page 28: ...Chapter 4 Installation Figure 4 6 VariFlame EDGE wiring diagram 28 Pneg 2091 VariFlame Heater...

Page 29: ...Chapter 4 Installation Figure 4 7 VariFlame EDGE schematic PNEG 2091 VariFlame Heater 29...

Page 30: ...Chapter 4 Installation Figure 4 8 Dipswitches 30 PNEG 2091 VariFlame Heater...

Page 31: ...NOTES PNEG 2091 VariFlame Heater 31...

Page 32: ...quivalents of the system IMPORTANT Use the ELOP value from this equation for size determination of all pipe sections Use the ELOP and the HVR of each pipe section to determine the required pipe size f...

Page 33: ...d choose the next larger value in the column In this example start with pipe section c e For pipe section c e HVR 40 000 BTUH 12 kW From Table 2 column 200 ft 40 12 is not listed NOTE The table values...

Page 34: ...0 3000 2650 2400 2250 2050 1950 18501 15000 1280 966 950 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 26506 2280 1855 1680 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 5...

Page 35: ...e regulator if applicable has been vented to the outside of the building Look at the gas hose for excessive abrasion wear or cuts Make sure that all external accessories have been installed and secure...

Page 36: ...ggle switch located on the left side of the control to the ON position Operating the burner 1 Make sure that inlet and discharge air are not restricted 2 Move the selector switch located on the electr...

Page 37: ...out large fluctuations Setting the kBtu correctly will also help heater efficiency Setting the output to low can cause the heater to run without reaching the setpoint Setting the output to high can ca...

Page 38: ...NOTES 38 PNEG 2091 VariFlame Heater...

Page 39: ...hing the outside of the heater 1 Spray the heater down with water only do not use cleaning solution 2 Wait at least one hour for the heater to completely dry before reconnecting the power cord to the...

Page 40: ...atch close the fuel supply valve to the heater and allow the remaining gas to burn off 6 Disconnect the heater from the electrical supply 7 Remove the gauges and reconnect the hoses 8 Close both press...

Page 41: ...Turn off the heater 2 Remove the threaded plug from the output pressure tap of the valve 3 Using a 1 8 MNPTadapter connect the hose of a pressure test kit NOTE Pressure test kit must read up to 15 in...

Page 42: ...the fan housing 5 3 Slide the control box mounting bracket 1 off of the screws 3 on the fan housing 5 4 Disconnect the wires from the control box that connect to the motor 5 Remove the ten screws 3 at...

Page 43: ...tails 10 Slide the four keyhole slots in the control mounting bracket 1 onto the screws 2 on the fan hous ing 5 and tighten the screws 11 Install the four screws 3 through the control box mounting bra...

Page 44: ...racket 4 Remove the two bolts 6 and nuts 7 securing the air proving switch 4 to the air proving switch mounting bracket 4 5 Slide the air proving switch 3 through the opening in the mounting plate 2 t...

Page 45: ...switch mounting bracket 1 Loosen screw 2 Mounting plate 3 Air proving switch 4 Mounting bracket 5 High limit switch Figure 6 6 Removing the air proving switch 2 Mounting plate 3 Air proving switch 4 A...

Page 46: ...e the two screws 1 securing the temperature high limit switch 5 from the mounting plate 2 To install the temperature high limit switch 5 Install the temperature high limit switch 5 to the mounting pla...

Page 47: ...ket 1 to the burner duct 2 Disconnect the igniter 3 and flame probe 4 from the control box 3 Slide the igniter flame probe mounting bracket 1 off of the screws to remove the probe assembly 4 Remove th...

Page 48: ...rvice and Maintenance Figure 6 9 Flame probe 1 Probe mounting bracket 2 Screw 3 Ignitor 4 Flame probe Figure 6 10 Flame probe 1 Probe mounting bracket 2 Screw 3 Ignitor 4 Flame probe 48 PNEG 2091 Vari...

Page 49: ...trol box 3 Slide the igniter flame probe mounting bracket 1 off of the screws to remove the probe assembly 4 Remove the the igniter 3 from the igniter flame probe mounting bracket 1 by removing the sc...

Page 50: ...nect all field wired connections from the board 3 Disconnect all heater electrical components from the board 4 Remove all screws connecting the board to the control box 5 Remove the control board To i...

Page 51: ...Chapter 6 Service and Maintenance Figure 6 13 Control Board Cover 7 Screw 8 Control cover Figure 6 14 Control Board 7 Screw 8 Control board PNEG 2091 VariFlame Heater 51...

Page 52: ...when installing 6 Using either pipe dope or thread tape approved for use with gaseous fuels install and tighten the gas valve to the burner pipe train The valve should be vertical when done 7 Turn the...

Page 53: ...Chapter 6 Service and Maintenance Figure 6 15 Remove supply valve 3 Supply line 6 Gas valve Figure 6 16 Gas valve removal 6 Gas valve PNEG 2091 VariFlame Heater 53...

Page 54: ...NOTES 54 PNEG 2091 VariFlame Heater...

Page 55: ...ter is awaiting a signal to start When the system light is flashing red there was an error present that has self corrected and the Airflow or Gas Valve error indicator lights will be flashing to deter...

Page 56: ...witch continuity with multimeter 3 Loss of airflow airflow was on but was then lost Sail switch state went off for more than 400ms when fan is ON Verify that fan motor is able to start Verify wiring t...

Page 57: ...stable flame after 3 tries from cold start Verify gas supply Verify valve wiring Verify flame sensor wiring Verify igniter condition and wiring Verify flame sensor rod for contact with metal housing...

Page 58: ...NOTES 58 PNEG 2091 VariFlame Heater...

Page 59: ...ntroller Parts Switch and Probe Parts Gas Parts Motor and Blower Wheel Parts VariFlame Controller Parts Figure 8 1 VariFlame EDGE Controller Parts Item Part Description 10 VF3 1056 Rocker Switch Panel...

Page 60: ...rts Item Part Description 1 3001 1740 Switch Micro with Sail Lever V3l 2 3005 0111 TSTAT TDISC 60T15 310D Airstream 3 VF1 1020 VariFlame Variable Rate Heater Control 11 VF1 3004 Hot Surface Igniter As...

Page 61: ...lve VariFlame Variable Rate LP 20 5071 NG Gas Valve VariFlame Variable Rate NG 10 VF3 1013 Ball Valve 1 4 Mnpt x 1 4 Fnpt Compact 11 VF2 3009 LP VariFlame Orifice Propane VF2 3010 NG X VariFlame Orifi...

Page 62: ...heel Parts Figure 8 4 Motor and Blower Wheel Parts Item Part Description 7 20 5099D Motor 1 3HP 1 Ph 120V 60 Hz C225m 8 20 5011X Wheel Blower Large C225m 50 Hz 9 20 5012 Spacer Tube 10 1001 2599 Lock...

Page 63: ...dy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paid for the product purchased This Warranty only covers the value of the warranted parts and equipment and do...

Page 64: ...llowed in all cases Authorities having jurisdiction should be consulted before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com...

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Cumberland VariFlame VF-16-ONG, Owner'S Manual

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