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Summary of Contents for Cumberland VariFlame VF-16-OPS
- 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 Use of this Equipment Information page will help you identify your equipment in the case that you need to notify the company. For this reason, this information should be filled out and kept on record. Equipment Information Model Number: Serial Number: Date Purchased: Dealer Name and Phone Number:...
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Page 3: Table Of Contents
Contents Chapter 1 Safety Precautions ........................5 Safety Guidelines ........................5 Cautionary Symbol Definitions......................6 Safety Precautions ........................7 Safety Decals ...........................12 Safety Sign-off Sheet.........................14 Chapter 2 Specifications .........................15 VariFlame vapor propane specifications ..................15 VariFlame natural gas specifications ...................16 Electrical and environmental specifications .................16 Timing specifications .........................17 Chapter 3 System Overview ........................19... - Page 4 NOTES PNEG-2091 VariFlame™ Heater...
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Page 5: Chapter 1 Safety Precautions
Safety Precautions Topics Covered in this Chapter ▪ Safety Guidelines ▪ Cautionary Symbol Definitions ▪ Safety Precautions ▪ Safety Decals ▪ Safety Sign-off Sheet Safety Guidelines Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is written to help you understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. -
Page 6: Cautionary Symbol Definitions
Chapter 1: Safety Precautions Cautionary Symbol Definitions Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use the symbols that are defined below. Table 1-1 Description of the different cautionary symbols Symbol Description... -
Page 7: Safety Precautions
Chapter 1: Safety Precautions Safety Precautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Respiratory Foot Protection Protection Protection Hearing Head Fall Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. •... - Page 8 Chapter 1: Safety Precautions Follow Safety Instructions • Warning: If the information in the manual is not followed exactly, a fire or explosion can result, causing property damage, personal injury or loss of life. • Carefully read all safety messages in this manual and safety signs on your machine.
- Page 9 • Do not attempt maintenance or repairs on the heater unless you are competent to do so. Understand service procedures before doing work. • Use only genuine Cumberland/AP parts when maintaining the heater. Use of other non-genuine parts is a misuse and may lead to dangerous situations.
- Page 10 Chapter 1: Safety Precautions Install and Operate Gas-Fired Equipment Properly • Gas-fired equipment should be installed by a qualified pipe fitter and must conform with local codes. • For Canada: The equipment shall be installed in accordance with the Natural Gas and Propane Installation Code, CSA B149.1, or the Propane Storage and Handling Code, CSA B149.2, or applicable provincial regulations, which should be carefully followed in all cases.
- Page 11 Chapter 1: Safety Precautions Install and Operate Electrical Equipment Properly • The electrical connections and grounding of the appliance shall be in compliance with the National Electric Code ANSI/ NFPA 70 for the United States or the Canadian Electrical Code for Canada, as well as all local and state codes. •...
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Page 12: Safety Decals
Chapter 1: Safety Precautions Safety Decals The safety decals on your equipment are safety indicators which must be carefully read and understood by all personnel involved in the installation, operation, service and maintenance of the equipment. Location Decal No. Decal Description Warning Electrical Hazard Inside door... - Page 13 Chapter 1: Safety Precautions Location Decal No. Decal Description On Door DC-2429 Caution Warning: Hot Surface On Door DC-2430 Over Heater Warning: Fire Hazard DC–2457 Outlet Cover To replace a damaged or missing decal, contact us to receive a free replacement. GSI Decals 1004 E.
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Page 14: Safety Sign-Off Sheet
Chapter 1: Safety Precautions Safety Sign-off Sheet Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety instructions. This sign-off sheet is provided for your convenience and personal record keeping. Date Employee Name Supervisor Name... -
Page 15: Chapter 2 Specifications
Specifications Topics Covered in this Chapter ▪ VariFlame vapor propane specifications ▪ VariFlame natural gas specifications ▪ Electrical and environmental specifications ▪ Timing specifications VariFlame vapor propane specifications Maximum input 250,000 (BTUH) Minimum input 50,000 (BTUH) Ventilation air required to support combustion 1,050 (CFM) Inlet gas supply pressure maximum 13.5 in. -
Page 16: Variflame Natural Gas Specifications
Chapter 2: Specifications VariFlame natural gas specifications Maximum input 250,000 (BTUH) Minimum input 50,000 (BTUH) Ventilation air required to support combustion 1,050 (CFM) Inlet gas supply pressure maximum 13.5 in. W.C. Inlet gas supply pressure minimum 7.0 in. W.C. Burner manifold pressure maximum 4.0 in. -
Page 17: Timing Specifications
Chapter 2: Specifications Table 2-1 Electrical and environment specifications (cont'd.) Gas Valve control output (Stepper RX) 0-5Vdc, 1mA (use on White-Rodger valve only) Variflame Controller - Environment Specifications Environment type Indoor use only Pollution Degree Installation Category or overvoltage category Protection against electric shock Class 1 classification... - Page 18 Chapter 2: Specifications Values Symbol Description Typical Parameter Unit Purge time that takes place imme- Post-purge diately following the shutting off of TPOPG 4950 5500 6050 time the fuel supply Period of time between the signal to de-energize the fuel flow means Recycle time following the loss of flame and the 4500...
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Page 19: Chapter 3 System Overview
System Overview Topics Covered in this Chapter ▪ Heater component functions ▪ Burner control module and sequence of operation Heater component functions Figure 3-1 VariFlame Components 1 — Blower motor and wheel assembly 5 — Flame Probe 2 — High Limit Switch 6 —... - Page 20 Chapter 3: System Overview High Limit Switch (2) Never bypass the high limit switch. Bypassing the limit switch can cause the heater to overheat. WARNING The high limit switch is a “normally closed” thermostat switch that limits the outlet temperature of the heater.
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Page 21: Burner Control Module And Sequence Of Operation
Chapter 3: System Overview Burner control module and sequence of operation Figure 3-2 VariFlame Sequence of Operation PNEG-2091 VariFlame™ Heater... - Page 22 Chapter 3: System Overview Power up and Initialization When you first turn on the VariFlame, it performs a self-check routine before starting up. If the following problems are detected, the controller goes into lockout mode: • A memory issue • AC frequency issue on the main sector •...
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Page 23: Chapter 4 Installation
Installation Topics Covered in this Chapter ▪ Installing the air diverter ▪ Installing for recirculating operation (indoor) ▪ Wiring Diagrams and Schematics ▪ Pipe sizing guidelines Installing the air diverter Air diverters are shipped flat and can be bent to direct the heated air as it exits the heater. 1. -
Page 24: Installing For Recirculating Operation (Indoor)
Chapter 4: Installation 4. Loosen the corner screws on the heater outlet cover (3) and remove the decal (4). 5. Slide the air divert over the screws (3). 6. Tighten the screws (3). Figure 4-2 Installing the air diverter IMPORTANT! — REMOVE DECAL 3 —... - Page 25 Chapter 4: Installation 7. Check all gas connections for leaks using a leak detector solution and repair any gas leak before placing the heater into service. 8. Install a sediment trap and a manual shut off valve to the heater’s gas inlet. 9.
- Page 26 Chapter 4: Installation Figure 4-4 Gas and Electrical Connections 1 — Sediment trap 4 — Vent to outside 7 — Regulator 9 — Heater 2 — Electrical cord 5 — Gas hose 8 — Shut-Off valve 10 — Air diverter 3 —...
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Page 27: Wiring Diagrams And Schematics
Chapter 4: Installation Wiring Diagrams and Schematics Use the wiring diagrams and schematics to connect components to the VariFlame Edge controller. Make sure all power sources are disconnected and locked out before performing any maintenance to the equipment. DANGER Figure 4-5 Inside VariFlame On-Off Controller PNEG-2091 VariFlame™... - Page 28 Chapter 4: Installation Figure 4-6 VariFlame EDGE wiring diagram Pneg-2091 VariFlame Heater...
- Page 29 Chapter 4: Installation Figure 4-7 VariFlame EDGE schematic PNEG-2091 VariFlame™ Heater...
- Page 30 Chapter 4: Installation Figure 4-8 Dipswitches PNEG-2091 VariFlame™ Heater...
- Page 31 NOTES PNEG-2091 VariFlame™ Heater...
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Page 32: Pipe Sizing Guidelines
Chapter 4: Installation Pipe sizing guidelines You must calculate the Heating Value Required (HVR) and Equivalent Length of Pipe (ELOP) for your installation. • Using a system schematic, label each piping section of the system starting at the meter or regulator. A different pipe section starts where the gas demand of the system changes, usually at a junction. - Page 33 Chapter 4: Installation No. Of Pipe Section HVR Calculation HVR Value Heaters BTUH BTUH 1 x 40,000 40,000 1 x 12 1 x 40,000 40,000 1 x 12 • Determine the ELOP. Length from meter to most remote heater = length from a to e (or g) = 100ft (30m) + 25ft (8 m) = 125ft (38 m) Minor loss equivalents from Table 1 = 1 gate valve x 2ft/valve (1 m/ valve) + 3 tees x 11 ft/tee (4 m/tee) =35ft (13 m).
- Page 34 Chapter 4: Installation IMPORTANT: The following tables are based on values given in the Gas Engineers Handbook and are intended as a guide only. Consult your gas supplier for gas capacity and pipe size informa- tion for your particular piping system. Table 4-3 Natural Gas (NG) Maximum Capacity Of Pipe In Thousands Of BTU per Hour Nominal...
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Page 35: Chapter 5 Startup And Operation
Startup and Operation Topics Covered in this Chapter ▪ Pre-startup inspections ▪ Emergency heater shutdown ▪ Normal heater shutdown ▪ Starting the heater ▪ Operating the burner ▪ Adjusting the heater output Pre-startup inspections • Look for any physical damage from shipping or installation that can cause the heater not to operate. •... -
Page 36: Starting The Heater
Chapter 5: Startup and Operation 4. Close the main gas supply valve. 5. Disconnect the main power supply. Starting the heater Before You Begin Make sure the heater has been installed properly by qualified gas and electrical service personnel. 1. Perform all pre-startup inspections. 2. -
Page 37: Adjusting The Heater Output
Chapter 5: Startup and Operation Adjusting the heater output The throttle valve in the On-Off VariFlame heater can be adjusted to increase or decrease the British ther- mal units (kBtu) of gas output. What You Should Know Depending on the ambient temperature or the age of the animals, you may want to adjust the output. The goal is to set the output best suited to allow the heater to maintain the setpoint without large fluctuations. - Page 38 NOTES PNEG-2091 VariFlame™ Heater...
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Page 39: Chapter 6 Service And Maintenance
Service and Maintenance Topics Covered in this Chapter ▪ Cleaning the heater ▪ Guidelines for checking gas pressure ▪ Checking the valve inlet pressure ▪ Checking the valve output pressure ▪ Replacing the motor and fan wheel ▪ Replacing the air proving switch ▪... -
Page 40: Checking The Valve Inlet Pressure
Chapter 6: Service and Maintenance • Close the fuel supply valve to the heater inlet. • Open the burner access panel and clean any dirt or debris from the gas control valve. What You Should Know Gas pressure entering the gas valve is Inlet Pressure. Gas pressure flowing out of the gas valve is Burner Manifold pressure. -
Page 41: Checking The Valve Output Pressure
Chapter 6: Service and Maintenance Failure to replace this plug can cause serious injury and death. WARNING Figure 6-1 On-off heater test port (inlet pressure check) Checking the valve output pressure 1. Turn off the heater. 2. Remove the threaded plug from the output pressure tap of the valve. 3. -
Page 42: Replacing The Motor And Fan Wheel
Chapter 6: Service and Maintenance Failure to replace this plug can cause serious injury and death. WARNING Figure 6-2 On-Off heater valve outlet test port (manifold pressure check) Replacing the motor and fan wheel Before You Begin • Disconnect all power sources to the heater. •... - Page 43 Chapter 6: Service and Maintenance NOTE: The red wire attaches to the same side of the motor capacitor as the white motor lead, and the black wire plugs into the black motor lead. (See wiring diagram for more details.) 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.
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Page 44: Replacing The Air Proving Switch
Chapter 6: Service and Maintenance Figure 6-4 Motor and fan wheel 3 — Screw 4 — Motor and fan assembly 5 — Fan housing Replacing the air proving switch Before You Begin • Disconnect all power sources to the heater. •... - Page 45 Chapter 6: Service and Maintenance Figure 6-5 Removing the air proving switch mounting bracket 1 — Loosen screw 4 — Mounting bracket 2 — Mounting plate 5 — High limit switch 3 — Air proving switch Figure 6-6 Removing the air proving switch 2 —...
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Page 46: Replacing The Temperature High Limit Switch
Chapter 6: Service and Maintenance Replacing the Temperature High Limit Switch Before You Begin • Disconnect all power sources to the heater. • Turn off the gas supply. To remove the temperature high limit switch: 1. Disconnect the two wires attached to the temperature high limit switch (4). 2. -
Page 47: Replacing The Flame Probe
Chapter 6: Service and Maintenance Figure 6-8 Temperature high limit switch 1 — Screw 2 — Mounting plate 8 — High limit switch Replacing the Flame Probe Before You Begin Both the igniter and flame probe can still be hot if the heater was in operation. Allow heater to cool completely before performing any maintenance. - Page 48 Chapter 6: Service and Maintenance Figure 6-9 Flame probe 1 — Probe mounting bracket 3 — Ignitor 2 — Screw 4 — Flame probe Figure 6-10 Flame probe 1 — Probe mounting bracket 3 — Ignitor 2 — Screw 4 — Flame probe PNEG-2091 VariFlame™...
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Page 49: Replacing The Ignitor
Chapter 6: Service and Maintenance Replacing the Ignitor Before You Begin Both the igniter and flame probe can still be hot if the heater was in operation. Allow heater to cool completely before performing any maintenance. CAUTION • Disconnect all power sources to the heater. •... -
Page 50: Replacing The Control Board
Chapter 6: Service and Maintenance Figure 6-12 Ignitor 1 — Probe mounting bracket 3 — Ignitor 2 — Screw 4 — Flame sensor Replacing the control board Before You Begin • Disconnect all power sources to the heater. • Turn off the main gas supply. To remove the control board: 1. - 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...
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Page 52: Replacing The Gas Valve
Chapter 6: Service and Maintenance Replacing the gas valve Before You Begin Turn off all gas supply before performing any maintenance on the gas supply lines. Failure to follow these instructions can result in bodily injury or death. WARNING • Disconnect all power sources to the heater. •... - 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...
- Page 54 NOTES PNEG-2091 VariFlame™ Heater...
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Page 55: Chapter 7 Troubleshooting
Troubleshooting Topics Covered in this Chapter ▪ Troubleshooting Troubleshooting LED Meanings • When the system light is “solid” red, there is an error currently present, and the Airflow or Gas Valve error indicator lights will be flashing to determine the cause of the error. •... - Page 56 Chapter 7: Troubleshooting Table 7-1 Blue LED Flash Descriptions (Airflow) Blue LED Error # of Cause Solution Description Flashes Unexpected airflow Verify that sail switch is in open position and that Sail Switch has been seen detected (air nothing can push on it when heater is idle. Verify closed when fan is off.
- Page 57 Chapter 7: Troubleshooting Table 7-2 Yellow LED Flash Descriptions (Gas Valve) Yellow LED Error # of Cause Cause and Solution Description Flashes Flame sensor signal has Verify that no flame is present in the system. Unexpected been seen active when it Verify flame sensor wiring.
- Page 58 NOTES PNEG-2091 VariFlame™ Heater...
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Page 59: Chapter 8 Parts
Parts Topics Covered in this Chapter ▪ VariFlame Controller 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 VF3-1056 Rocker Switch, Panel Mount, On-Off, CSA/UL PNEG-2091 VariFlame™... -
Page 60: Switch And Probe Parts
Chapter 8: Parts Switch and Probe Parts Figure 8-2 Switch and Probe Parts Item Part Description 3001-1740 Switch Micro with Sail Lever V3l 3005-0111 TSTAT TDISC 60T15 310D Airstream VF1-1020 VariFlame Variable Rate Heater Control VF1-3004 Hot Surface Igniter Assembly VF1-3002 Flame probe assembly PNEG-2091 VariFlame™... -
Page 61: Gas Parts
Chapter 8: Parts Gas Parts Figure 8-3 Gas Parts Item Part Description 20–50702 (LP) Gas Valve, VariFlame Variable Rate, LP 20–5071 (NG) Gas Valve, VariFlame Variable Rate, NG VF3-1013 Ball Valve, 1/4 Mnpt x 1/4 Fnpt, Compact VF2-3009 (LP) VariFlame Orifice, Propane VF2-3010 (NG) X VariFlame Orifice, Natural Gas VF3-1008... -
Page 62: Motor And Blower Wheel Parts
Chapter 8: Parts Motor and Blower Wheel Parts Figure 8-4 Motor and Blower Wheel Parts Item Part Description 20-5099D Motor, 1/3HP, 1 Ph, 120V, 60 Hz / C225m 20-5011X Wheel, Blower / Large - C225m 50 Hz 20–5012 Spacer Tube 1001–2599 Lock Nut PNEG-2091 VariFlame™... -
Page 63: Gsi Group, Llc Limited Warranty
Chapter 8: Parts Limited Warranty — N.A. Grain Products The GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months from the date of shipment (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge). - Page 64 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.com AP and Cumberland are a part of GSI, a worldwide brand of AGCO Corporation. Copyright © 2017 by The GSI Group, LLC Printed in the USA CN #339598...
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