PROPANE CONVERSION INSTRUCTIONS. Applies to: Gas-Fired, Tubular Radiant, Low-Intensity Infrared Heater

Transcription

1 PROPANE CONVERSION INSTRUCTIONS Applies to: Gas-Fired, Tubular Radiant, Low-Intensity Infrared Heater

2 Section 1 Section 2 Burner orifice plate replacement (all models) Flame plate attachment (all models) Section 3a Gas injector replacement (all 60kBTU to 150kBTU models only) Section 3b Gas injector replacement (all 169kBTU to 200kBTU models only) Section 4 Section 5 Baffle plate attachment (all 60kBTU to 100kBTU models only) Refitting burner head (all models) Section 6a Gas valve LP conversion (VP1) Section 6b Gas valve LP conversion (VP2, VC1/2) Section 7a Air pressure switch replacement (200kBTU VP1) Section 7b Air pressure switch replacement (200kBTU VP2, VC1/2) Section 8a Fan orifice plate replacement (3 fixings VP1) Section 8b Fan orifice plate replacement (4 fixings VP1) Section 8c Fan orifice plate replacement (3 fixings VP2, VC1/2) Section 8d Fan orifice plate replacement (4 fixings VP2, VC1/2) Section 9 Data badge replacement (all models) Section 10a Technical data and gas pressures (VP1/VC1) Section 10b Technical data and gas pressures (VP2/VC2) Section 11 Re-commissioning (all models) Section 12 Component part numbers (all models) Natural Gas Model/BTU per hour Conversion Kit Part Number (VP1/VC1) Conversion Kit Part Number (VP2/VC2) High Altitude LP Conversion Available LP Gas Model/BTU per hour AFTER CONVERSION 18/60, YES 18/60,000 25/80, YES 25/80,000 30/100, YES 30/100,000 38/123, YES 38/125,000 45/150, YES 45/150,000 50/169, VP1/VC1 ONLY VP1/VC1 45/150,000 VP2/VC2 50/169,000 60/200, NO 50/169,000 These are generic conversion kits for each rating. Any extra components that come with the conversion kit need to be disposed of accordingly.

3 VP1 Model P R B Q H L M S Part Code B H L M P Q R S Description Gas Valve Gas injector Pressure Switch Gaskets Burner Orifice Plate Flame Plate Location (plate not shown) Fan Orifice Plate Baffle Plate Location (plate not shown) VP2, VC1/2 Models Q R P S L H M B

4 Section 1 Burner Orifice Plate Replacement (all models) Step 1 Remove the four retaining screws, set of two screws either side of the burner casting, using a no. 2 crosshead screwdriver. Step 5 Remove the brass impulse stud and grommet from the old orifice plate and attach to the replacement orifice plate. Step 2 Remove the supporting casting and gasket. Step 6 Fit new propane burner orifice plate to burner tube ensuring the impulse stud is facing the correct direction. Two new gaskets are provided and should be used when reconnecting to the burner housing. Dispose of the old gaskets. See Section 10 for correct burner orifice plate identification. Section 2 Step 3 The burner head assembly can be disconnected by separating the connectors of the ignition lead assembly and removing the ground lead and pressure switch silicon tube. Flame Plate Attachment (all models) Step 1 Remove the three screws holding the burner head in place with a no. 2 crosshead screwdriver. Step 2 Discard the spacer bracket indicated below. Step 4 The burner orifice plate can then be released by removing the 3 fixing screws from the burner tube using a no.2 crosshead screwdriver. Step 3 Align the flame plate with the 5 holes on the outer edge of the burner head.

5 Step 4 Attach to the burner tube using the screws removed in step 1. Ensure the flame plate is mounted on top of the original burner head. See Section 10 for flame plate identification. Section 3a Step 2 Carefully insert the baffle plate at an angle through the combustion chamber opening, making sure that the holes are positioned towards the holes at the front of the burner box. For VC burners there will already be 2 screws located in these holes. Remove these screws before proceeding. Gas Injector Replacement (all 60kBTU to 150kBTU models only) Step 1 Using a 12mm wrench remove the gas injector from the jet carrier by rotating anti-clockwise. Step 2 Replace the gas injector with the propane alternative ensuring an approved gas sealant is used on the thread. DO NOT OVERTIGHTEN. Step 3 Align the holes and screw the baffle plate to the burner box using the self tapping screws supplied. See Section 10 for gas injector identification. Section 4 Baffle Plate Replacement (all 60kBTU to 100kBTU models only) Step 1 Locate the baffle plate in the LP conversion kit.

6 Section 5 Refitting Burner Head (all models) Section 6a Gas Valve LP Conversion (VP1) Step 1 Reconnect the ignition lead, ground lead and pressure switch silicon tube. Take care to pass the leads and silicone tube through the gasket. New gaskets are provided and the old gaskets should be disposed of accordingly. Step 1 To gain access to the gas valve loosen screw in burner lid and open the right hand burner access door. Step 2 Remove the gas valve regulator cover screw (brass). Step 3 Remove the adjustment screw (white) beneath cover screw. Step 4 Remove natural gas regulator spring (colorcoded silver/plain) from regulator sleeve. Step 2 Locate the burner head assembly over the gas injector ensuring the leads do not get pinched between the orifice plate and burner housing. Step 3 Refit the gasket and casting over the burner head tube and fix with the original screws. Step 5 Insert the LP regulator spring (provided in the conversion kit and color-coded white) into the regulator sleeve. Step 6 Replace the regulator adjustment screw and adjust approximately 8 turns. Step 7 Attach warning label to outside of burner housing where it can be readily seen.

7 Step 8 Retain small round LP labels for use after the burner has been adjusted to the correct outlet pressure. Section 6b Gas Valve LP Conversion (VP2, VC1/2) VP2 / VC2 burners have a two-stage gas valve. VC1 burners have a single stage gas valve. Step 1 To gain access to the gas valve remove the bottom access panel by removing the 4 screws with a no. 2 crosshead screwdriver. Step 2 Remove the gas valve regulator cover screw/ screws (brass). Step 3 Remove the adjustment screw/screws (white) beneath cover screw/screws. Step 4 Remove the natural gas regulator spring/springs (color-coded silver/plain) from regulator sleeve/sleeves. Step 5 Insert the LP regulator spring/springs (provided in the conversion kit and color-coded white) into the regulator sleeve/sleeves. Step 6 Replace the regulator adjustment screw/screws and adjust approximately 8 turns. Step 7 Attach warning label to outside of burner housing where it can be readily seen.

8 Step 4 Fit the new air pressure switch (with a red label) ensuring the cables and terminal cap are installed correctly and the silicon tubes are connected as shown below. Step 8 Retain small round LP labels for use after the burner has been adjusted to the correct outlet pressure. Section 7a Air Pressure Switch Replacement (200kBTU VP1) Step 1 To gain access to the pressure switch loosen screw in burner lid and open left hand access door. The pressure switch has a brown label. Step 2 Disconnect the silicone tubes, cables and terminal cap from the pressure switch. Step 5 Close access door and tighten screw in burner lid. Section 7b Air Pressure Switch Replacement (200kBTU VP2, VC1/VC2) Step 1 The pressure switch can be accessed by removing the top panel at the rear of the burner. This is secured by 4 screws. Step 3 Remove the two screws as shown below. Step 2 Disconnect the silicone tubes, cables and terminal cap from the pressure switch.

9 Step 3 Remove the two electrical chassis retaining screws. Step 4 The air pressure switch can now be removed by unscrewing from the back plate. It may be necessary to partially disconnect the chassis wiring to access the pressure switch mounting screws at the rear. Step 5 Fit the new air pressure switch (with a red label) ensuring the cables and terminal cap are installed correctly and the silicon tubes are connected as shown below. Step 2 Fit the replacement fan orifice plate. Reattach the 3 x 8mm nuts turning clockwise, using the wrench to secure the new orifice plate to the combustion fan. Take care not to cross thread the fasteners. See Section 10 for correct fan orifice plate identification. For high altitude conversion see Section 10 for correct high altitude fan orifice plate identification. Section 8b Fan Orifice Plate Replacement (4 fixings VP1) Step 1 Using a no.2 crosshead screwdriver remove the four screws securing the fan orifice plate and remove. Step 5 Close access door and replace the fixing screws. Section 8a Fan Orifice Plate Replacement (3 fixings VP1) Step 1 Remove the nuts that secure the fan orifice plate with an 8mm wrench. Slide the fan orifice plate off the threaded studs.

10 Step 2 Fit the replacement fan orifice plate and secure with the same four screws. Take care not to cross thread the screw fixings. Section 8c Section 8d Fan Orifice Plate Replacement (4 fixings VP2, VC1/2) Step 1 Remove fan following procedure in Section 8c. Step 2 Follow procedure in Section 8b to change the fan orifice plate. Step 3 When complete refit the fan and cover. Fan Orifice Plate Replacement (3 fixings VP2, VC1/2) Step 1 Remove the top cover of the burner using a no.2 crosshead screwdriver to expose the combustion fan. Section 9 Data Badge Replacement (all models) Ensure the single stage LP conversion label is used on VP1/VC1 burners and the two-stage LP conversion label is used when converting VP2/VC2 burners. Step 1 Locate the LP conversion data label. Step 2 Indicate the altitude setting of the appliance by placing an X in the appropriate box highlighted below. Step 2 Remove the four screws which have been highlighted, thee of which can not be seen in the photograph. Lift out the fan assembly to access the fan. Step 2 Affix over the technical data section of the natural gas data label as shown below. Step 3 Follow the procedure in Section 8a to change the fan orifice plate. Step 4 When complete refit the fan and cover.

11 Section 10a Technical Data and Gas Pressures (VP1/VC1) CONNECTOR MUST BE INSTALLED IN A U CONFIGURATION. FOR HEATERS UPTO 150,000 BTU/H, A 24 LONG CONNECTOR OF AT LEAST ½ ID MUST BE USED. FOR HEATERS ABOVE 150,000 BTU/H, A 36 LONG CONNECTOR OF AT LEAST ¾ NOMINAL ID MUST BE USED. Connector must be certified for use on a radiant tube type infrared heater and must comply with Standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 or with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas, CAN/CGA 8.1. NOTE: For Canada all heaters MUST use a hose 36 long Gas Type LP/Propane Gas Required Gas Pressure (in W.C) (60,000 TO 150,000 BTU) 11.0 Required Gas Pressure (in W.C) (169,000 TO 200,000 BTU) 11.0 Max Supply Pressure (in W.C) 14.0 Gas Supply Connection ½ N.P.T thread VP1 / VC1 Model/BTU per hour Burner Orifice Plate Injector LP Gas ft (0-610m) Injector Size Injector Pressure Pressure Switch Flame Plate Part No. Part No. mm Inches WC. Part No. Part No. 18/60, x /80, x /100, x /123, x /150, x /169,000* x /200,000** x CANADA ONLY 10% DERATE Model/BTU per hour Burner Orifice Plate Injector LP Gas ft ( m) Injector Size Injector Pressure Pressure Switch Flame Plate Part No. Part No. mm Inches WC. Part No. Part No. 18/60, x /80, x /100, x /123, x /150, x /169,000* x /200,000 N/A * De-rated from 169kBTU to 150kBTU. ** De-rated from 200kBTU to 169kBTU, not suitable for high altitude.

12 Flame Plate Identification VP1 / VC1 Model/BTU per hour 18/60,000 Fan Type VP1 Fan Type VC1 LP Gas ft (0-610m) Combustion Fan Details Orifice Part No. Qty Holes 10mm sq. Qty Fixings /80, /100, /123, /150, /169,000* /200,000** CANADA ONLY 10% DERATE Model/BTU per hour 18/60,000 Fan Type VP1 Fan Type VC1 LP Gas ft ( m) Combustion Fan Details Orifice Part No. Qty Holes 10mm sq. Qty Fixings /80, /100, /123, /150, /169,000* /200,000 N/A * De-rated from 169kBTU to 150kBTU. ** De-rated from 200kBTU to 169kBTU, not suitable for high altitude.

13 Section 10b Technical Data and Gas Pressures (VP2/VC2) CONNECTOR MUST BE INSTALLED IN A U CONFIGURATION. FOR HEATERS UPTO 150,000 BTU/H, A 24 LONG CONNECTOR OF AT LEAST ½ ID MUST BE USED. FOR HEATERS ABOVE 150,000 BTU/H, A 36 LONG CONNECTOR OF AT LEAST ¾ NOMINAL ID MUST BE USED. Connector must be certified for use on a radiant tube type infrared heater and must comply with Standard for Connectors for Gas Appliances, ANSI Z21.24/CSA 6.10 or with the Standard for Elastomeric Composite Hose and Hose Couplings for Conducting Propane and Natural Gas, CAN/CGA 8.1. NOTE: For Canada all heaters MUST use a hose 36 long Gas Type LP/Propane Gas Required Gas Pressure (in W.C) (60,000 TO 150,000 BTU) 11.0 Required Gas Pressure (in W.C) (169,000 TO 200,000 BTU) 11.0 Max Supply Pressure (in W.C) 14.0 Gas Supply Connection ½ N.P.T thread VP2 / VC2 Model/BTU per hour Burner Orifice Plate LP Gas ft (0-610m) Injector Injector Size Injector Pressure Part No. Part No. mm Inches WC. High 18/60, x Low Pressure Switch Part No. Flame Plate Part No /80, x /100, x /123, x /150, x /169,000*** x /200,000** x CANADA ONLY 10% DERATE Burner Orifice Plate LP Gas ft ( m) Injector Injector Size Injector Pressure Pressure Switch Flame Plate Model/BTU per hour Part No. Part No. mm Inches WC. High 18/60, x Low Part No. Part No /80, x /100, x /123, x /150, x /169,000 60/200,000 N/A *** Not suitable for high altitude. ** De-rated from 200kBTU to 169kBTU, not suitable for high altitude.

14 Flame Plate Identification VP2 / VC2 Model/BTU per hour 18/60,000 Fan Type LP Gas ft (0-610m) Combustion Fan Details Orifice Part No. Qty Holes 10mm sq /80, /100, /123, /150, /169,000*** /200,000** Qty Fixings CANADA ONLY 10% DERATE Model/BTU per hour Fan Type Orifice Part No. 18/60,000 LP Gas ft ( m) Combustion Fan Details Qty Holes 10mm sq. Qty Fixings /80, /100, /123, /150, /169,000 60/200,000 + No fan orifice plate change required. *** Not suitable for high altitude. N/A ** De-rated from 200kBTU to 169kBTU, not suitable for high altitude.

15 Section 11 Re-commissioning (all models) Check installation has been carried out to these instructions. Replace burner on tube and secure. Reconnect gas hose. Open Manual valve. Check soundness. Open control housing and check that all components are securely fastened. Check thermostat is set to maximum and is calling for heat. Switch on electrical supply. The red neon should now be illuminated. If restarting heater a delay of 15sec should be allowed. The heater should now run through its start up sequence and ignite. Turn off power and check that all components are securely fastened. NO A successful ignition is indicated by the amber light illuminating and remaining illuminated. Has the burner lit? YES Check gas pressure. Check operation on flame failure. Check gas pressure. Leave the instructions with a responsible person. Close control housing. Check operation of air pressure switch. Once gas outlet pressure has been set replace gas valve regulator cover screw/screws and attach round LP label/labels to the top of the regulator cover screw/screws.

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