Powrmatic CPx30, User, Installation And Servicing Instructions

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Page 18 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014
Electrical Connections
Wiring external to the air heater must be installed in accor-
dance with the I.E.E. Regulations for Electrical Installations
and any local regulations which apply. Wiring should be
completed in flexible conduit.
Heaters are for use with 230V, 1N, 50Hz or 400V, 3N, 50Hz
supplies (see heater data plate).
The method of connection to the main electricity supply
must:-
- facilitate the complete electrical isolation of the heater(s)
that will prevent remote activation of the heater during
servicing.
- be in a readily accessible position adjacent to the heater(s).
- serve only the heater(s).
- have a contact separation of at least 3mm in all poles. See
the wiring diagram for the heater electrical connections.
All units are fully prewired and only require final connections
for the incoming mains supply. Heaters not supplied with
inbuilt time and temperature controls will also require
completion of the external control circuit (230V) via a room
thermostat, time clock etc. and, if applicable, the remote low
level lockout reset.
All heaters must be earthed.
Reference must be made to Table 3 Page 21 to ascertain the
electrical loading of the unit(s) being installed so that cables
of adequate cross-sectional area are used for the electrical
installation. The length of the conductors between the cord
anchorage and the terminals must be such that the current
carrying conductors become taut before the earth conductor
if the cable or cord slips out of the cord anchorage. All exter-
nal controls must be of an approved type.
Heaters supplied less main fan must be electrically
interlocked to the air movement system so that this is started
in the same manner as the air heater fan would be viz. A
connection from the appropriate heater terminal (see wiring
diagram with the heater) must be made to one side of the fan
motor contactor coil, the other side of the coil being connect-
ed to Neutral. Under no circumstances must the fan motor
electrical supply be taken direct from the internal wiring of
the heater.
A = 2 core and earth (Single Phase)
4 core and earth (Three Phase)
B = Powrtrol = 4 core and earth
Powrtrol RR = 4 core and earth
MC200 = 4 core and earth
C = 2 core screened (MC200 model only)*
*(screen must be grounded only
at the MC200)
2.5.1 Electrical Installation
Checks to ensure electrical safety must be completed by
a competent person.
2.5.2 Gas Installation (if applicable)
The whole of the gas installation, including the meter,
should be inspected and tested for soundness and
purged in accordance with the recommendations of
IGE/UP/1 or IGE/UP1A or IGE/UP/1B as appropriate.
2.5.3 Oil Installation (if applicable)
The whole of the oil installation, including the tank, should
be inspected and tested in accordance with the recom-
mendations of OFTEC.
2.5.4 Air Distribution System
The system should be checked to ensure that the instal-
lation work has been carried out in accordance with the
design requirements.
Particular attention should be given to the correct
arrangement of delivery ducts and registers, return air
ducts and grills and general adequacy of return air paths.
For CPx*/D heaters ensure that the total duct system
resistance does not exceed the available air pressure of
the equipment supplied refer to Table 2 (Page 21). If the
duct system resistance is less than the available air pres-
sure of the equipment supplied additional resistance must
be introduced e.g. by adjustment of duct outlet nozzles
and balancing of the duct system. Conversely if the duct
system resistance is greater than the available air pres-
sure of the heater supplied the system resistance must be
reduced.
2.5.5 Lighting the Air Heater
Note: The limit thermostat interlock relay will
require resetting after loss of the electrical supply
to the heater regardless of whether the limit
thermostat has operated.
2.5.5.1 Gas Fired Heaters
Note: Refer also to the burner instruction booklet
supplied with the heater. This provides informa-
tion on how to adjust the burner, setting up the air
pressure switches, system checks and fault
finding detail.
Note: DO NOT use burner settings from the
burner instruction booklet. The burners are
specifically adjusted for Powrmatic heaters, only
use the settings in these instructions.
2.5.5.1.1 Gas Controls Assembly –
Soundness Check
1. Ensure the gas service valve at the inlet to the gas
controls assembly is shut.
2. To prove soundness of the first main safety shut-off
valve:-
a) Connect pressure gauge to the inlet pressure test point
on the main valve block or inlet pipework.
b) Open gas service valve and allow pressure to stabilize
before shutting it again. The valves are sound if no pres-
sure drop is observed. If a pressure drop is observed do
not proceed until the fault has been rectified. Remove
pressure gauge and refit sealing screw in pressure test
point.
2.5.5.1.2 Sequence Check
1. Ensure that the gas service valve is closed and that the
main electrical supply to the heater is switched off.
2. Start the burner by setting the time clock and thermo-
stat to call for heat or complete the external control circuit.
3. Turn ON the main electrical supply, press the limit inter-
lock relay reset switch and check that the following
sequence of events occurs.
i) Burner fan runs.
ii) Ignition spark is heard.
iii) Start gas valves open (Main gas valves on CP-G100 -
300).
iv) Burner goes to lockout as there is no gas supply.
4. Switch OFF main electricity supply.
2.5.5.1.3 Final Adjustment
2.5.5.1.3.1 CPxG 30 – 90
1. Remove the sealing screw from the pressure test point
located on the side of the gas inlet to the burner head and
attach a pressure gauge. Remove the sample point cover
plug from the outlet flue length and insert a CO2 measur-
ing instrument.
2. Turn ON the main electricity supply, press the limit inter-
lock relay reset switch and check that the following
sequence of events occur.
i) Burner fan runs.
ii) Ignition spark is heard.
iii) Main gas valves open and main gas flame is estab-
lished.
3. Check that the main burner gas pressure agrees with
that stated on the heater data plate. If necessary adjust
the main burner gas pressure (Fig 2 Page 21) by rotating
the adjustment screw under the cover flap. If the range of
adjustment does not allow for setting of the correct burner
pressure the main volume regulator may also be used. It
is recommended that the main governor adjustment is
within 50% to 75% of its range.
4. Measure the CO2 content of the flue gases. If neces-
sary adjust the combustion air damper of the burner
(Refer to the Burner Instructions) to obtain a reading of
9.0 - 9.5%
5. Turn OFF the burner, remove pressure gauge and refit
sealing screw in pressure test point and flue sample point
cover plug.
Pressure adjustment
Screw under cover
Main volume regulator
Fig 2 Dungs valve
Pressure adjustment
2.5.5.1.3.2 CPxG 120 – 300
1. Remove the sealing screw from the pressure test point
located on the side of the gas inlet to the burner head and
attach a pressure gauge. Remove the sample point cover
plug from the outlet flue length and insert a CO2 measur-
ing instrument.
2. Turn ON the main electrical supply, press the limit inter-
lock relay reset switch and the burner will run through its
sequence until main flame is established. Check that the
main burner gas pressure agrees with that stated on the
heater data plate. If necessary adjust the main burner gas
pressure (Fig 2) by rotating the adjustment screw under
the cover flap. If the range of adjustment does not allow
for setting of the correct burner pressure the main volume
regulator may also be used. It is recommended that the
main governor adjustment is within 50% to 75% of its
range.
3. Measure the CO2 content of the flue gases. If neces-
sary adjust the combustion air damper of the burner
(Refer to the Burner Supplement) to obtain a reading of
9.0 - 9.5%.
4. Turn OFF the burner. Remove pressure gauge, refit
sealing screw in pressure test point and flue sample point
cover plug.
2.5.5.1.4 Final Soundness Test
1. After making final gas rate checks all joints on the gas
controls assembly must be tested for soundness using
leak detection fluid/electronic leak detector.
2.5.5.1.5 Flame Safeguard
1. Whilst the burner is in operation close the gas service
valve. The burner should go to lockout within 1 second.
2.5.5.1.6 Air Pressure Switch
Note:
Refer to the burner instruction booklet but
follow the steps below. The air pressure switch is
nearest the front of the burner.
1. The air pressure switch is set after all other
adjustments have been made.
2. Begin with the switch at the lowest setting. With
the burner working at the minimum output, adjust
the dial clockwise, increasing its value until the
burner shuts down. Now reduce the value by one
set point, turning the dial anti-clockwise.
3. Check for reliable burner operation, if the
burner shuts down, reduce the value by a half set
point.
2.5.5.1.7 Over Pressure Switch
Note: Refer to the burner instruction booklet but
follow the steps below. The over pressure switch
is furthest from the front of the burner.
1. The maximum air pressure switch must be set
after all other adjustments have been made.
2. Begin with the switch at its highest setting and
the burner working at the correct input for high
fire.
3. Slowly adjust the pressure switch dial
anti-clockwise, to decrease the set point, until the
burner locks out. Immediately stop adjustment.
4. Now increase the set point by 0.1mb and
restart the burner.
5. If the burner fails to start, or shuts down due to
the pressure surge on ignition, increase the pres-
sure switch setting by a further 0.1mb and restart
the burner.
6. Continue until the burner reliably starts
2.5.5.2 Oil Fired Heaters
Note: Refer also to the burner instruction booklet
supplied with the heater. This provides
information on how to adjust the burner, setting up
the air pressure switches, system checks and
fault finding detail.
Note: DO NOT use burner settings from the
burner instruction booklet. The burners are
specifically adjusted for Powrmatic heaters, only
use the settings in these instructions.
2.5.5.2.1 Initial burner startup
1.Check that fuel is present in the tank and at the oil filter
fitted on the front of the heater.
2. Check that fitted fire valves are open.
3. Refer to the burner instruction book and fit a pressure
gauge (and vent valve if the burner is on a single pipe oil
feed) to the oil pump.
4. Set the time clock and thermostat to call for heat or
complete the external control circuit.
5. Turn ON the main electrical supply, press the limit inter-
lock relay reset switch and check that the burner fan
starts.
6. Note: This step is only for when a vent valve is
being used.
Open the vent valve. When air free oil issues
from the vent valve close the valve and the
burner will fire when the ignition spark is present.
(Note: This procedure may need to be repeated
several times if the oil line cannot be purged of air
within one ignition cycle. At the end of the unsuc-
cessful ignition cycle the burner will go to lockout.
Wait 2/3 minutes and then depress the red reset
button on the burner control box to restart the
ignition cycle.)
7. After completion of the pre-purge period the ignition
spark will be energised and the burner oil solenoid valve
will open and the burner will light.
Warning: If burner ignition cannot be achieved after 2-3
attempts do not continue to recycle through the ignition
sequence but ascertain the cause and rectify.
WARNING:
If continued unsuccessful ignition attempts are
made it is possible to accumulate a significant
quantity of oil and oil mist in the combustion
chamber which, if the burner then fires, can result
in a dangerous situation. Any such accumulation
of oil must be removed by safe means before
any further attempt to light the burner.
2.5.5.2.2 Final Adjustment
1.Remove the sample point cover plug from the outlet flue
length and insert a CO2 measuring instrument.
2. Relight the burner. Check that the pump pressure is as
specified on heater data plate. If adjustment of the pump
pressure is necessary refer to the burner instructions and
complete.
3. Measure the CO2 content of the flue gases. If neces-
sary adjust the combustion air damper of the burner
(Refer to the Burner Instructions) to obtain a reading of
11.5 - 13.0%.
4. Turn OFF the burner. Remove pressure gauge and refit
sealing plug, refit flue sample point cover plug.
2.5.5.2.3 Final Checks
1. After making final adjustments check that there are no
leaks on the oil pipework.
2.5.6 Main Air Fan/ Fan Stat
Ensure that the fan and limit settings are as follows:-
Fan ON - 122°F (50°C), Fan OFF - 86°F (30°C)
Limit
CPx 30 - 90, 150 - 175 212°F (100°C)
CPx 120 230°F (110°C)
CPx 200 - 300 248°F (120°C)
Note:
The new L4064B may be supplied with the
limit temperature mechanically limited to less
than the setting required. To release the mechan
ical limit push a pointed object into the small hole
at the top of the dial. At the same time prevent the
dial from rotating and push the limit temperature
adjuster around to the required setting.
On ducted units ensure that the main air fan comes on no
later than 150 to 180 seconds after the main burners light.
2.5.7 Handing over the Air Heater
Hand these instructions to the user or purchaser for reten-
tion and instruct the User in the efficient and safe opera-
tion of the air heater.
In the event that the premises are not yet occupied turn
off the gas and electricity supplies and leave instructional
literature with the heater.
WARNING: Always switch off and disconnect
electricity supply, close the gas service valve or
turn off the oil supply before carrying out any
servicing work or replacement of failed compo-
nents.
4.1.1 General
Full maintenance should be undertaken not less than
once per year. After any servicing work has been com-
plete or any component replaced the air heater(s) must
be fully commissioned and tested for fuel tightness as
described in Section 2.5. Page 17
4.1.2 Burner Servicing/Maintenance
1. Refer to the burner instructions supplied with the
heater and complete the servicing/maintenance instruc-
tions therein. Note: In the case of gas burners ignore any
references in the burner supplement to the gas controls
assembly.
4.1.3 Heat Exchanger Cleaning
1. Removing the upper rear panel of the heater exposes
the heat exchanger rear clean out panel.
2. Removing the fan/limit thermostat(s) as described in
4.1.6.6.4, Page 25 disconnecting the flue and then
removing the upper front panel of the heater exposes the
heat exchanger front clean out panels. If the flue cannot
be disconnected removal of the side panels exposes the
upper front header side clean out plates.
3. Remove the nuts securing the clean out panel(s) as
appropriate and remove panel(s).
4. If heat exchanger baffles are fitted, withdraw them.
5. Brush through heat exchanger tubes and remove loose
material using a vacuum cleaner.
6. If it is necessary to also gain access to the combustion
chamber disconnect the fuel and electrical connections
from the burner. Remove the nuts securing the burner to
the heater and withdraw the burner from the burner tube.
7. Reassemble all components in reverse order. Note:
Replace any gaskets with new ones.
4.1.4 Fan Assembly
1. Remove the lower panels of the heater to gain access
to the fan section.
2. Inspect the fan blades to see that they are not dam-
aged and that there is no excessive build up of deposits
that could give rise to an imbalance. If necessary clean
the fan blades using a stiff brush and vacuum cleaner.
3. Replace panels accordingly.
4.1.5 Oil Filter (if applicable)
1. Release the securing bolt, or unscrew the filter bowl, to
access the filter.
2. Clean the filter or replace as deemed necessary.
3. Refit bowl ensuring that seals are correctly in place.
4.1.6 Replacement of Faulty
Components
4.1.6.1 Burner Components
1. Refer to the burner instructions supplied with the heater
for information regarding replacement of components
within the burner.
4.1.6.2 Gas Controls Assembly (if
applicable)
1. Remove the electrical connections from the gas control
block.
2. Release the nuts securing the inlet and outlet flanges to
the gas control block and lift out the gas control block. Fit
the replacement assembly in reverse order ensuring the
valve is correctly orientated =for the direction of gas flow.
4.1.6.3 Main Air Fan and Motor
Important: On 3ph heaters fitted with 3ph main
fan motors ensure that the fan direction of
rotation corresponds with the direction of rotation
arrow on the fan guard or case. If necessary
reverse the direction of rotation by interchanging
any two of the motor live leads at the terminal
strip in the electrical panel. Should it be neces-
sary to remove one or more of the fans for clean-
ing proceed as follows.
4.1.6.3.1 CPx 30 - CPx 120
Note: These heaters are fitted with direct drive
fan units.
1. Disconnect the fan motor electrical leads from
the terminal strip (Refer to wiring diagram
supplied with the heater)
2. Remove the two screws, one on each side of
the fan mounting flange, that secure the fan to the
fan shroud.
3. Remove the screws securing the heat
exchanger mounting frame to the fan shroud on
the side that the fan is going to be withdrawn.
4. Withdraw the fan from the slide rails.
5. Reassemble in reverse order.
4.1.6.3.2 CPx 150 - CPx 300
Note: These units are fitted with belt driven main
air fans.
1.Remove the lower side panel(s).
2. Release the motor mounting plate securing
screws and then remove the belt tension by
turning the tension adjustment screw anticlock
wise. Remove the fan belts.
3. Remove the screws securing the fan mounting
feet to the heater framework and remove the fan.
It may be necessary to re-orientate the fan within
the fan compartment and also to release the fan
shroud fixings in order to pass the fan through
the heater frame. On units with twin or triple fan
sets on a common fan shaft it will be necessary to
first remove the fan shaft.
4. Inspect the fan belts and if necessary replace
with new.
5. Replace components in reverse order.
6. Do not over tension the fan belts. There should
be approximately 15mm of deflection when
downward pressure is applied to the belt(s)
halfway between the motor and fan pulleys.
Fig 3 Fan belt tension setting
4.1.6.6.4 Fan / Limit Thermostat Hon-
eywell L4064B
NOTE: Larger heaters have two fan and limit
thermostats fitted.
Either one will start the main fans and either one
will shut down the burner in the event of an over-
heat situation.
1. Squeeze the sides of the cover and remove
cover by pulling forward.
2. Release wiring from clamp terminals by push-
ing a small screwdriver into the clamp release
holes adjacent to the clamps.
3. Remove the 2 screws securing the thermostat
to the heater panel and withdraw thermostat.
4. Reassemble new unit in reverse order referring
to the heater wiring diagram to ensure correct
wiring location.
Important:
A replacement fan/limit thermostat
may have a brass link between the bottom fan
terminal and the bottom limit terminal (situated in
the slot between the two terminals). This MUST
be removed, by breaking the link off using a pair
of thin nose pliers, before the replacement
thermostat is installed.