Powrmatic CA-G series Installation Instructions Manual

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The CA-G Range

CE

BSI Registered Firm

FM 414

Ind. & Comm. Air Heaters;

Air Moving Equipment;

Flues & Chimneys; Natural

HEATING DIVISION

Winterhay Lane

Ilminster, Somerset TA19 9PQ

Tel: [phone] Fax: [phone]

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Smoke & Heat Ventilators;
Powered Supply & Extract

Fans & Systems.

Installation and Servicing

Instructions

W ARNING: THIS APPLIANCE MUST BE EARTHED

CA G Issue 6 January 1998

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CONTENTS

Section Title Page

1. Introduction 2

2. Technical Data 3

3. General Requirements 6

4. Installation 8

5. Air Distribution System 9

6. Commissioning & Testing 9

7. Servicing 12

8. Connections to Powrmatic
External Controls 14

9. Fault Finding 14

10. Short List of Parts 16

Tables Title Page

1a. Dimensions (S.I. Units) 4
1b. Dimensions (Imperial Units) 4
2a. Specifications (S.I. Units) 4
2b. Specifications (Imperial Units) 5

3.1 Burner Pressures - Natural Gas
Group H - G20 5

3.2 Burner Pressures - Propane - G31 5

4. Electrical Loadings 6

Figure Title Page

1a. Gas Control Schematic CA-G 100 - 300 10
1b. Gas Control Schematic CA-G 400 - 2000 10
2a. Gas Controls Layout CA-G 100, 150 11
2b. Gas Controls Layout CA-G 200, 300 11
2c. Gas Controls Layout CA-G 400 - 2000 11

3. Belt Tension Adjustment 12

4. Honeywell L4064N 13

5. White Rodgers 5F464 13

Appendix Title Page

A Calculation of Flue System Equivalent 16

Resistance

1

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1. INTRODUCTION

The Powrmatic CA-G range of gas fired forced draught, closed
flue, fanned circulation air heaters cover a heat output range of

29.3 kW (100000 Btu/h) to 586.2 kW (2000000 Btu/h) and are
intended primarily for heating commercial or industry premises.
They are certified for use on Natural Gas, Group H - G20 and
Propane - G31.

Models CA-G 400 - CA-G 2000 in UF and UD variants are for floor
mounting whilst all models are available in CF, CD, HF and HD
variants for mounting at high level. (U - Upright; C - Counterflow;
H - Horizontal; F - Freeblowing; D - Ducted).

CA-G heaters have a centrifugal fan assembly fitted upstream of
the combustion chamber / heat exchanger assembly to circulate
the air being heated. The CA-G ###**/D range, in having no fan
fitted, is for ducted systems where the air moving fan is by
others.
Heaters are fitted as standard with fully automatic monoblock
forced draught gas burners and monoblock gas control
assemblies.

Options include High/Low or modulating burners, Deep V
filters, proportional air dampers, combustion air inlet adaptors
and inlet and outlet duct spigots.

Each air heater must be connected to a closed flue system only.

Gas Safety (Installation & Use) Regulations 1994

It is law that all gas appliances are installed, adjusted and, if
necessary, converted by qualified persons* in accordance with
the above regulations. Failure to install appliances correctly can
lead to prosecution. It is in your own interests and that of safety
to ensure that the law is complied with.
* e.g. Corgi Registered

2

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2 Technical Data

DC

G

E

HB

L

L

KA

F

2.1 Dimensions

CA-G 400 - 2000 UF & UD Models

D

D

F

G

E

H
B

FRONT SIDE

CA-G 400UF SHOWN

J

K
A

CA-G 100 - 2000 CF & HD Models

HB

F

C

H
B

FRONT SIDE

CA-G 800HD SHOWN

G

E

J

K
A

CA-G 800UF SHOWN

C

E

G

D

C

F

B
H

E

G

CA-G 200HD SHOWN

KA

A
K

J

C

G

3

F

CA-G 800CF SHOWN

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Table 1a. Dimensions (S.I. Units)

A B C D #1 D #2 E F G H J K L

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

730 603 1645 254 211 775
806 629 1822
857 730 2076 1080

1060 908 2356 309 217 1035 2058 808 525 960

1568 1010 1873

2025 1162 2229 1295 200 1936 1062
2432 1391 2788 1295 300 2420 1291 2332

2737 1695 3016 1524 300 2616 1593 655 2635

203 178

356 283

406 317

Table 1b. Dimensions (Imperial Units)

A B C D #1 D #2 E F G H J K L

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

28.75 23.75 64.75 10 8.3 30.5

31.75 24.75 71.75

33.75 28.75 81.75 42.5

41.75 35.75 92.75 12 8.5 40.75 81 37.75 20.75 37.75

61.75 39.75 73.75

79.75 45.75 87.75

95.75 54.75 109.75

107.75 66.75 1188.7 60 103 62.75 103.75

8 7

14 11.1

16 12.5

1390 503 502 630

914 1530 529 527 706

1055 175 1562 910 525 1468

41.5 7 61.5 56.75 20.75 56.75

125

1810 630 629 757

150

1925

655

54.75 24.75 14.75 24.75

36 60.25 27.75 17.75 27.75

51

5

71.25 29.75 24.75 29.75

6

8 76.25 75.75

95.25 91.75 91.75

12

75.75

25.75

50

2

Table 2a - Specifications (S.I. Units)

MAXIMUM DUCT

RESISTANCE

MODEL

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

HIGH FIRE LOW FIRE

INPUT

(Nett)

103.0 88.0 N/A N/A 1.5575 250 N/A 1.5 N/A 304

133.8 117.2 N/A N/A 2.0766 150 N/A 2.2 N/A 381

161.5 146.5 N/A N/A 2.9736 160 175 1.5 2.2 405

202.1 175.8 N/A N/A 3.4000 150 190 2.2 3.3 405

235.0 205.1 N/A N/A 3.9647 120 200 2.2 3.3

262.0 234.5 N/A N/A 4.5075 70 175 2.2 3.3 584

332.0 293.1 N/A N/A 5.1919 220 250 4.0 5.5 889

499.5 439.6 N/A N/A 7.7880 200 250 2 x 5.5 2 x 7.5 1397

678.7 586.2 N/A N/A 10.3840 155 250 2 x 7.5 2 x 11.0 Rc2 1930

OUTPUT

kw kw m³/s pa kw

32.1 29.3 N/A N/A 0.5192 150 N/A 0.335 N/A

48.4 44.0 N/A N/A 0.7788 290 N/A 0.55 N/A 177

67.0 58.6 N/A N/A 1.0383 200 N/A 0.56 N/A

INPUT

(Nett)

OUTPUT Standard L.H.P. Standard L.H.P.

AIR

VOLUME

4

FAN MOTOR

Gas

Connection

Size

Rc½

Rc¾

Rc1½

WEIGH

kg

152

177

405

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Table 2b - Specifications (Imperial Units)

MAXIMUM DUCT

RESISTANCE

FAN MOTOR

Gas

Connection

Size

½"BSP

¾"BSP

1½"BSP

WEIGH

lb

335

390

893

MODEL

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

HIGH FIRE LOW FIRE

INPUT

(Gross)

OUTPUT

Btu/h Btu/h ft³/m in wg hp

INPUT

(Gross)

OUTPUT Standard L.H.P. Standard L.H.P.

AIR

VOLUME

121694 100000 N/A N/A 1100 0.60 N/A 0.45 N/A

183489 150000 N/A N/A 1650 1.16 N/A 0.75 N/A 390
254004 200000 N/A N/A 2200 0.80 N/A 0.75 N/A
390483 300000 N/A N/A 3300 1.00 N/A 2.0 N/A 670
507249 400000 N/A N/A 4400 0.60 N/A 3.0 N/A 840
612263 500000 N/A N/A 6300 0.64 0.70 2.0 3.0 893
766257 600000 N/A N/A 7200 0.60 0.76 3.0 4.5 893
891098 700000 N/A N/A 8400 0.48 0.80 3.0 4.5
993268 800000 N/A N/A 9550 0.28 0.70 3.0 4.5 1287
125864 100000 N/A N/A 11000 0.88 1.00 5.5 7.5 1960
189365 150000 N/A N/A 165000 0.80 1.00 7.5 10.0 3080
257313 200000 N/A N/A 220000 0.62 1.00 10.0 15.0 2"BSP 7281

Table 3.1 Burner Pressures - Natural Gas - Group H - G20 - Net CV (Hi) = 34.02MJ/m³

MODEL

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

Powrmatic Burners Riello Burners

Type

Start Gas
Pressure

mbar mbar mbar mbar m³/h ft³/h

Main Burner

Pressure

Type

Start Gas
Pressure

Main Burner

Pressure

PCGS 2 N/A 4.8 GS 5 N/A 4.3 3.40 120.1
PCGS 2 N/A 9.9 GS 10 N/A 4.2 5.12 180.8
PCGS 3 N/A 12.2 GS 10 N/A 3.7 7.08 250.0
PCGS 5 N/A 10.4 GS 10 N/A 5.2 10.89 384.6
PCGS 5 1.5 8.8 GS 20 2.4 4.2 14.14 499.3
PCGS 5 1.1 8.2 GS 20 2.4 5.4 17.07 602.8

PCGS 8 2.5 9.7 GS 20 2.8 5.9 21.37 754.7
PCGS 13 3 9.2 GAS 3 1.3 6.0 24.85 877.6
PCGS 13 1.5 5.8 GAS 3 1.3 7.0 27.70 978.2
PCGS 13 2.4 9.0 GAS 3 3.5 9.5 35.10 1239.5
PCGS 25 1.2 9.0 GAS 5 0.75 7.0 52.86 1866.7
PCGS 35 4.6 8.1 N/A N/A N/A 71.82 2536.4

Gas Rate

Table 3.2 Burner Pressures - Propane - G31 - Net CV (Hi) = 88.00MJ/m³

Powrmatic Burners Riello Burners

MODEL

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000
CA-G 1500
CA-G 2000

Start Gas

Type

Pressure

PCGS 2 N/A 6.9 GS 5 N/A 3.1 1.31 46.3
PCGS 2 N/A 11.3 GS 10 N/A 6.4 1.98 69.9
PCGS 3 N/A 20.0 GS 10 N/A 4.1 2.74 96.8
PCGS 5 N/A 14.2 GS 10 N/A 8.3 4.21 148.7
PCGS 5 3.5 23.4 GS 20 2.5 5.9 5.47 193.2
PCGS 5 2.6 20.5 GS 20 2.5 6.8 6.60 233.1

PCGS 8 1.9 22.8 GS 20 3.0 8.9 8.26 291.7
PCGS 13 1.0 12.0 GAS 3 2.8 13.1 9.61 339.4
PCGS 13 1.2 15.8 GAS 3 2.5 13.5 10.71 378.2
PCGS 13 2.0 22.5 GAS 3 4.3 21.0 13.57 479.2
PCGS 25 2.3 27.5 GAS 5 2.8 18.0 20.43 721.5
PCGS 35 3.2 26.5 N/A N/A N/A 27.24 962.0

Main Burner

Pressure

mbar mbar mbar mbar m³/h ft³/h

Type

Start Gas

Pressure

Main Burner

Pressure

5

Gas Rate

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Table 4 Electrical Loadings

Standard Larger Horsepower Motor

MODEL

CA-G 100
CA-G 150
CA-G 200
CA-G 300
CA-G 400
CA-G 500
CA-G 600
CA-G 700
CA-G 800
CA-G 1000

CA-G 1500

CA-G 2000

NOM.

ph

MOTOR

R.P.M.

1000 2.6 5.0 2.6 3
1500 5.0 8.5 6.1 7

1

1000

3

1500

PLATE

AMPS

(A)

4.1 10.0 4.5 5

7.0 18.0 8.1 10

6.7 14.0 3.3 7

3.55 16.0 3.8 5

5.2 14.0 5.2 7 7.4 25.0 6.8 7

5.2 25.0 5.7 7 7.4 26.0 8.8 10

5.2 27.0 5.2 5 7.4 25.0 7.8 10

8.7 30.0 9.7 10 12.0 37.0 12.5 15

2 x 12.0 2 x 38.0 2 x 13.0 30

2 x 15.1 2 x 46.0 2 x 16.0 35

START

AMPS

(A)

RUN AMPS

(A)

FUSE

RATING

(A)

NOM.

MOTOR

R.P.M.

1500

PLATE

AMPS

15.1

23.1

START

AMPS

(A)

5.2 14.0 4.8 5

2 x

2 x

(A)

N/A

2 x

48.0
2 x

70.0

RUN

AMPS

(A)

2 x

15.5
2 x

22.0

FUSE

RATING

(A)

35

50

3. General Requirements

3.1 Related Documents

The installation of the air heater(s) must be in accordance with
the rules in force and the relevant requirements of the Gas Safety
Regulations, Building Regulations and the I.E.E. Regulations for
Electrical Installations.
It should be in accordance also with any relevant requirements
of the local gas region, local authority and fire authority and the
relevant recommendations of the following documents.

British Gas Plc Publications

IM/11 : 1989 Flues for Commercial and Industrial Gas Fired
Boilers and Air Heaters
IM/16 : 1988 Guidance notes for the installation of gas pipework,
boosters and compressors in Customers premises (excluding
domestic installation of 25mm and below).

British Standards Code of Practice

BS 5588 Fire precautions in the design and construction of
buildings.
Part 2 : 1985 Code of Practice for Shops
Part 3 : 1983 Code of Practice for Office Buildings
BS 6230: 1991 Installation of Gas Fired Forced Convection Air
Heaters for Commercial and Industrial Space Heating.

location must also provide adequate space for servicing and air
circulation around the air heater.
The heater(s) must not be installed in conditions for which it is
not specifically designed e.g. where the atmospheric is corrosive
or salty and where high wind speeds may affect burner operation,
and they are not suitable for outdoor use.
Where the location of the air heater is such that it might suffer
external mechanical damage e.g. from overhead cranes, fork lift
trucks, it must be suitably protected.
CA-G units are designed to operate in a maximum ambient
temperature of 25 °C.

3.3 Gas Supply

3.3.1 Service Pipes

The local gas undertaking should be consulted at the installation
planning stage in order to establish the availability of an adequate
supply of gas. An existing service pipe must not be used without
prior consultation with the local gas undertaking.

3.3.2 Meters

A gas meter is connected to the service pipe by the local gas
undertaking or a local gas undertaking contractor. An existing
meter should be checked, preferably by the gas undertaking, to
ensure that the meter is adequate to deal with the total rate of gas
supply required.

Those appliances having an input rating not exceeding 60kW
viz. CA-G 100 and CA-G 150 must be installed in accordance with
the relevant recommendations of the following documents.
BS 5440 Flues and Air Supply for gas appliances of rated input
not exceeding 60kW (1st and 2nd family gases).
Part 1 - Flues, Part 2 - Air Supply

3.3.3. Installation Pipes

Installation pipes should be fitted in accordance with
IM/16:1988. Pipework from the meter to the air heater must be of
adequate size. Do not use pipes of a smaller size than the inlet
gas connection of the heater. The complete installation must be
tested for soundness as described in the above Code. The
complete installation must be tested for soundness as described

For CA-G 100 and CA-G 150 units reference should also be made

in BS 6230.

to BS 5864. Code of Practice for installation of gas-fired ducted­air heaters of rated input not exceeding 60kW.

3.3.4. Boosted Supplies

Where it is necessary to employ a gas pressure booster the

3.2 Location

The location chosen for the air heater must permit the provision
of a satisfactory flue system and an adequate air supply. The

controls must include a low pressure cut off switch at the booster
inlet. The local gas undertaking must be consulted before a gas
pressure booster is fitted.

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3.4 Flue System

Detailed recommendations for fluing are given in BS 5440, Part
1 (Flues) and IM/11.

The air heater must be connected to a closed flue system. The
cross sectional area of the flue serving the appliance must be not
less than the area of the flue outlet to the air heater.
Materials used for the flue system should be mechanically
robust, resistant to internal and external corrosion,
noncombustible and durable under the conditions to which they
are likely to be subjected.
Prevention of condensation within the flue should be an important
factor in the design of the flue system. In order to minimise
condensation the use of double walled flue pipe or insulation is
recommended. If double walled flue pipe is used it should be of
an acceptable type.
Where condensation in the flue is unavoidable provision should
be made for condensation to flow freely to a point at which it can
be released, preferably into a gully. The condensation pipe from
the flue to the disposal point should be of non-corrodible
material of not less than 22mm (1/2") size.
Facilities should be made for disconnecting the flue pipe(s) from
the air heater(s) for inspection and servicing purposes. Bends
with removable covers should be fitted for inspection and
cleaning purposes where considered appropriate.
The flue should terminate in a freely exposed position and must
be so situated as to prevent the products of combustion entering
any opening in a building in such concentration as to be
prejudicial to health or a nuisance.
It is recommended that consideration be given to the fitting of
a terminal at the flue outlet, however, where the heater flue is less
than 200mm (8") in diameter an approved terminal must be fitted.

3.5 Air Supply

In buildings having a design air change rate of less than

0.5 /h, and where CA-G heaters are to be installed in heated
spaces having a volume less than 4.7 m3 /kW of total rated heat
input grilles shall be provide at low level as follows:-

(1) for heaters of heat input less than 60 kW, the

total minimum free area shall not be less than

4.5 cm2 per kilowatt of rated heat input.

(2) for heaters of heat input 60 kW or more, the

total minimum free area shall not be less than
270cm2 plus 2.25 cm2 per kilowatt in excess

of 60 kW rated heat input.
The air vent(s) should have negligible resistance and must not
be sited in any position where it is likely to be easily blocked or
flooded or in any position adjacent to an extraction system
which is carrying flammable vapour.

Where the air heater(s) is to be installed in a plant room the air
heater(s) requires the plant room housing it to have permanent
air vents communicating directly with the outside air, at high
level and at low level. Where communication with the outside air
is possible only by means of high level air vents, ducting down
to floor level for the lower vents should be used.
Air vents should have negligible resistance and must not be
sited in any position where they are likely to be easily blocked
or flooded or in any position adjacent to an extraction system
which is carrying flammable vapour.
Grilles or louvres should be so designed that high velocity air
streams do not occur within the plant room.

The basic minimum effective area requirements of the air vents
are as follows:

(a) Low Level (inlet)

(1) for heaters of total rated heat input less than 60 kW:

9 cm2 per kilowatt of rated heat input

(2) for heaters of total rated heat input 60 kW or more:

540 cm2 plus 4.5 cm2 per kilowatt in excess of
60 kW total rated input.

(b) High Level (outlet)

(1) for heaters of total rated heat input less than 60 kW:

4.5 cm2 per kilowatt of rated heat input;

(2) for heaters of total rated heat input 60 kW or more:

270 cm2 plus 2.25 cm2 per kilowatt in excess of
60kW total rated input.

3.6 Air Distribution System

The following notes are of particular importance.
For free-blowing units it must be taken into account that the
buoyancy of the heated air leaving the heater and air patterns
within the space being heated will modify the air throw pattern
achieved. In buildings having a low heat loss where single units
are required to cover a large floor area and in buildings with high
roof or ceiling heights Calecon thermal economiser units should
be fitted to ensure even heat distribution and minimise
stratification respectively. Care should be taken to avoid
impeding the air throw with racking, partitions, plant or machinery
etc. Various outlet configurations are available as optional
extras to modify the air throw pattern to suit particular site
conditions.

For ducted units all delivery and return air ducts, including air
filters, jointing and any insulation or lining must be constructed
entirely of materials which will not contribute to a fire, are of
adequate strength and dimensionally stable for the maximum
internal and external temperatures to which they are to be
exposed during commissioning and normal operation. In the
selection of materials account must be taken of the working
environment and the air temperatures which will result when the
overheat limit thermostat is being commissioned. Where inter­joist spaces are used as duct routes they should be suitably lined
with a fire-resisting material.
A full and unobstructed return air path to the air heater(s) must
be provided.
If the air heater(s) is installed in a plant room the return air
intake(s) and the warm air outlet(s) from the heater(s) must be
fully ducted, in to and out of the plant room to avoid interference
with the operation of the flue by the air circulation fan.
The openings in the structure of the plant room through which
the ducting passes must be fire stopped.
Care must be taken to ensure that return-air intakes are kept clear
of sources of smells and fumes, and in special circumstances
where there is any possibility of pollution of the air by dust,
shavings etc., precautions must be taken by carefully positioning
return air intakes and by the provision of screens to prevent
contamination.
In addition, where there is a risk of combustible material being
placed close to the warm air outlets, suitable barrier rails should
be provided to prevent any combustible material being within
900mm (3ft) of the outlets.

3.7 Electrical Supply

Wiring external to the air heater must be installed in accordance
with the I.E.E. Regulations for Electrical Installations and any

7

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local regulations which apply. Wiring should be completed in
flexible conduit.
Heaters CA-G 100 - CA-G 300 are supplied by 230V - 1ph, 50Hz.,
the remaining heaters by 400V - 3ph, 50Hz. The method of
connection to the main electricity supply must facilitate the
complete electrical isolation of the air heater(s) and the supply
should serve only the air heater(s).
The isolator must have a contact separation of at least 3mm in
all poles. The method of connection should be provided adjacent
to the air heater(s) in a readily accessible position.
See the accompanying wiring diagram for the heater electrical
connections.

4. Installation of Air Heater(s)

4.1 General

Before installation, check that the local distribution condi­tions, nature of gas and pressure, and adjustment of the appli­ance are compatible.

The air heater must be installed in accordance with the rules in
force and the relevant requirements of any fire regulations or
insurance companys requirements appertaining to the area in
which the heater is located, particularly where special risks are
involved such as areas where petrol vehicles are housed, where
cellulose spraying is carried out, in wood working departments
etc.
Whichever method of mounting the air heater is used the
following minimum clearances for installation and servicing
must be observed.

To the front The depth of the heater
To the rear 1.0m (3.3ft)
To at least one side 1.0m (3.3ft)
Above the heater 1.00m (3.3ft)

Heaters mounted at high level must not be installed at a height
of less than 1.8m (5.9ft)
Any combustible material adjacent to the air heater and the flue
system must be so placed or shielded as to ensure that its
temperature does not exceed 65 °C (150 °F).

IMPORTANT:

1. No air heater shall be installed where there is a foreseeable
risk of flammable particles, gases vapours or corrosion inducing
gases or vapours being drawn into either the heated air stream
or the air for combustion. In such cases installation may only
proceed if the air to be heated and the air for combustion are
ducted to the heater from an uncontaminated source preferably
outside the building. In certain situations where only airborne
particles are present it may suffice to fit filters on the air inlet
ducts of the heater. Advice in these instances may be obtained
from Powrmatic Ltd.

4.2 Fitting the Air Heater

Floor mounted heaters must be installed on a level
noncombustible surface.
Suspended heaters must be installed either on specifically
designed cradles or platforms that are capable of adequately
supporting the weight of the unit (See Tables 2a and 2b, Page

5) and allowance must be made for any ancillary equipment.
Before installing the heater any existing trusses, walls, brackets
etc., must be inspected to ensure they are suitable. All supports

should be protected against the effects of rust or corrosion. The
means of mounting should also provide for service access
wherever possible.
If noise levels are of particular importance the heater should be
insulated from the structure of the building by installing it on
suitable anti-vibration mountings. In all such cases and, in
addition, when the heater is suspended it is essential that all gas,
duct, electrical and flue connections to the heater are made with
flexible connections to maintain continuity of connection. In the
case of the flue connection single wall stainless steel flue is
deemed to flex sufficiently to meet the requirements.

4.3 Connection of Air Heater(s) to Flue
System

A single wall Tee piece is supplied with each heater and must be
fitted to the flue outlet socket on the heater. The flue system then
connects directly on to the tee. For flue sizes refer to Tables 1a
and 1b Page 4 . All units must be fitted with a flue having a
minimum height, from the heater to the flue terminal, of 2m (6.5ft).
Horizontal runs of flue are not permitted.
If necessary a single offset using two 45° bends can be included
to avoid obstructions. The maximum equivalent resistance of
the flue system must not exceed 20 pa. Details of how to calculate
the resistance of the flue to be installed are given in Appendix
A.

4.4 Condensate Drainage

The design of the flue system should minimise the formation of
condensation, however when this is envisaged to be a problem
provision should be made for condensation to flow to a joint
where it can be drained, preferably into a gully.

4.5 Gas Connection

A servicing valve and downstream union must be fitted at the
inlet to the air heater gas controls assembly to facilitate servicing.
The gas supply to the air heater must be completed in solid
pipework and be adequately supported.

WARNING

When completing the final gas connection to the heater do not
place undue strain on the gas pipework of the heater.

4.6 Electrical Connections

All units are fully pre-wired and only require final connections
for the incoming mains supply and completion of the control
circuit (230V) via a room thermostat, time clock etc. The electrical
supply must be run to a point adjacent to the heater and be
suitably terminated to provide an isolation point that will prevent
remote activation of the unit during servicing. The heater
electrical panel is located behind the lower front panel and cable
entry points are provided in the adjacent heater framework.
Reference must be made to Table 4 (Page 6) to ascertain the
electrical loading of the air heater(s) being installed so that
cables of adequate cross-sectional area to safely carry that load
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 external controls must be of an approved type.

See the wiring diagram accompanying these instructions.

When installing CA-G D models they must be electrically
interlocked to the air movement system so that this is started in

8

Supplied By www.heating spares.co Tel. [phone]

the same manner as the air heater fan would be.
A connection from heater terminal No 9 must be made to one side
of the fan motor contactor coil, the other side of the coil being
connected to Neutral. Under no circumstances must the fan
motor electrical supply be taken direct from the internal wiring
of the heater.

5. Air Distribution System

5.1 General

CA-G *D models are designed for use with duct work to more
precisely define the point of air delivery, and /or provide ducted
return air or ducted fresh air inlet. All ducting must be
independently supported of the air heater. Joints and seams of
supply ducts and fittings must be securely fastened and made
airtight.

5.2 Noise Reduction

If deemed necessary consideration should be given to mounting
the heater on resilient pads, or equivalent, to minimise transfer
of noise and vibration to the structure of the building.
It is recommended that ducting should be connected to the
heater spigots via an airtight flexible coupling of noncombustible
material. Before fitting coupling it must be ensured that a
maximum clearance of 13mm (1/2") will be maintained between
the ends of the ducting and the heater spigots.
If required sound attenuators may be fitted in inlet and outlet
ducts to reduce airborne fan noise. Materials used in outlet
sound attenuators must be capable of withstanding 100 °C air
temperature without any deterioration.

5.3 Room Thermostat Siting

The room thermostat should be fitted at a point which will be
generally representative of the heated area as far as temperature
is concerned. Draughty areas, areas subjected to direct heat e.g.
from the sun, and areas where the air movement is relatively
stagnant e.g. in recesses, are all positions to be avoided for siting
the thermostat.
The thermostat should be mounted about 1.5m (5ft) from the
floor.
Any room thermostat, frost thermostat, time clock etc. must be
suitable for switching 230V, 5A and must be of the 'snap action'
type to minimise contact bounce.

For electrical connections of external controls see the
accompanying wiring diagram.

6. Commissioning & Testing

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 CA-G *D heaters ensure that the total duct system resistance
does not exceed the available air pressure of the equipment
supplied refer to Table 2a & 2b (Page5). If the duct system
resistance is less than the available air pressure of the equipment
supplied additional resistance must be introduced e.g. by
adjustment of duct outlet nozzles and balancing of the duct
system.

6.4 Lighting the Air Heater

6.4.1 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 and

first start gas 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 stabilise

before shutting it again. The valves are sound if no
pressure drop is observerved. 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.

6.4.2 Sequence Check

1. Ensure that the gas service valve is closed and that the main

electrical supply to the heater is switched off.

2. Check that all external controls are either "ON" or at "MAX"

3. Turn "ON" the main electrical supply 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 CA G100 -300).

iv) Burner goes to lockout as there is no gas supply.

4. Switch off main electricity supply.

6.4.3 Final Adjustment

6.4.3.1 CA-G 100 - 300

IMPORTANT: The maxium flow and start flow adjustments
provided on the GM main gas block valve assembly
(Fig 2b - 4) are not used and must not be adjusted.

6.1 Electrical Installation

Checks to ensure electrical safety must be carried out by a
qualified person.

6.2 Gas Installation

The whole of the gas installation, including the meter, should be
inspected and tested for soundness and purged in accordance
with the recommendations of IM/16:1988.

6.3 Air Distribution System

The system should be checked to ensure that the installation
work has been carried out in accordance with the design

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 measuring instrument.

2. Turn "ON" the main electricity supply and check that the

following sequence of events occur.
i) Burner fan runs.
ii) Ignition spark is heard.
iii) Main gas valves open

3. Check that the main burner gas pressure agrees with that in

Tables 3.1 or 3.2. If necessary adjust the main burner gas
pressure (Fig 2a - 3 or Fig 2b - 2).

4. Measure the CO2 content of the flue gases. If necessary adjust

9

Main gas flame is established.

Supplied By www.heating spares.co Tel. [phone]

the combustion air damper of the burner (Refer to the Burner
Supplement) to obtain a reading of 9.0 - 9.5%

5. Turn "OFF" the main electricity supply, remove pressure
gauge and refit sealing screw in pressure test point and flue
sample point cover plug.

6.4.3.2 CA-G 400 - 2000

IMPORTANT: The maxium flow and start flow adjustments
provided on the GM main gas block valve assembly
(Fig 2c - 4) are not used and must not be adjusted.

6. Turn "ON" the main electrical supply and the burner will run
through its sequence untill main flame is established. Check
that the main burner gas pressure agrees with that in Tables 3.1
or 3.2. If necessary adjust the main burner gas pressure

(Fig 2c - 3).

7. Measure the CO2 content of the flue gases. If necessary
adjust the combustion air damper of the burner (Refer to the
Burner Supplement) to obtain a reading of 9.0 - 9.5%.

8. Remove pressure gauge, refit sealing screw in pressure test
point and flue sample point cover plug.

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 measuring instrument.

2. Remove the electrical cover from the downstream main gas
valve and pull apart the inline connector.

3. Turn "ON" the main electricity supply and check that the
following sequence of events occur.
i) Burner fan runs.
ii) Ignition spark is heard.
iii) Start gas valves open.
iv) Start gas flame is established.

4. Check that the start gas pressure agrees with that in Tables

3.1 or 3.2. If necessary adjust the start gas pressure (F ig 2c - 5).

4. Turn "OFF" the main electricity supply.

5. Reconnect the inline connector and refit valve electrical cover.

Gas Controls Schematics

Fig 1a CA-G 100 - 300

1st Main Gas
Safety Shut-off Valve

PTP

6.4.4 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.

6.4.5 Flame Safeguard

1. Whilst the burner is in operation close the gas service valve.
The burner should go to lockout within 1 second.

6.5 Handing over the Air Heater

Hand the Users Instructions to the user or purchaser for
retention and instruct in the efficient and safe operation of the
air heater and associated controls.
Adjust the automatic controls to those values required by the
User.

2nd Main Gas
Safety Shut-off
Valve

PTP

Fig 1b CA-G 400 - 2000

1st Main Gas
Safety Shut-off Valve

PTP

1st Safety
Shut-off Valve

To BurnerGas Inlet

Main Gas Governor

2nd Main Gas
Safety Shut-off
Valve

PTP

To BurnerGas Inlet

Main Gas Governor

2nd Safety
Shut-off Valve

Start Gas Governor

10

Supplied By www.heating spares.co Tel. [phone]

Fig 2a Gas Controls Layout CA-G 100, 150

1) 1st Main gas safety shut off valves.

2) 2nd Main gas safety shut off valves.

3) Main burner pressure adjustment screw.

Notes:­i) Electrical connection plugs not shown.

Fig 2b Gas Controls Layout CA-G 200, 300

1) Main gas safety shut
off valves.

2) Main burner pressure
adjustment screw.

3) Inlet Pressure test
point.

4) Flow rate and valve
opening speed
adjustments.

Gas Inlet

1

2

To BurnerGas Inlet

3

1243

T

E

P

S

O

.

I

G

N

E

T

R

T

R

A

T

X

S

V

A

M

V

To Burner

Fig 2c Gas Controls Layout CA G 400 - 2000

6

T

E

P

S

O

.

I

G

N

E

T

R

Gas Inlet

1

3

1) Main gas safety shut off valves.

2) Start gas safety shut off valves.

3) Main burner pressure adjustment screw.

4) Flow rate and valve opening speed adjustments.

5) Start gas pressure adjustment screw.

6) Pressure test point.

T

R

A

T

X

S

V

A

M

V

To Burner

4

25

11

Supplied By www.heating spares.co Tel. [phone]

Finally, advise the user or purchaser that, for continued efficient
and safe operation of the air heater, it is important that servicing
is carried out annually.
In the event that the premises are not yet occupied turn off the
gas and electricity supplies and leave instructional literature
adjacent to gas meter.

7. Servicing

WARNING: Always switch off and disconnect electricity supply
and close the gas service valve before carrying out any servicing
work or replacement of failed components.

NOTE:

If a suspended air heater is to be serviced do not lean ladders
against the heater. Ensure that an access tower or equivalent is
used.

7.1 General

Full maintenance should be undertaken not less than once per
year. After any servicing work has been completed or any
component replaced the air heater(s) must be fully commissioned
and tested for soundness as described in Section 6.

7.2 Burner Maintenance

1. Refer to the Burner Supplement supplied with the heater.
Note: Any references therein to the gas controls assembly
should be ignored.

7.3 Heat Exchanger Cleaning

1. Disconnect the gas supply at the inlet to the gas controls
assembly.

2. Disconnect the electrical connections from the heater electrical
panel to the buner at the burner.

3. Remove the nuts securing the burner to the heat exchanger
and remove the burner.

4. Rear Flued Heaters only
a. Remove the fan/limit thermostat as described in 7.5.4
b. Remove the upper front panel of the heater to expose
the heat exchanger clean out panel.

Front Flued Heaters only

a. Remove the upper rear panel of the heater to expose the
heat exchanger clean out panel.

5. Remove the nuts securing the panel and remove the panel.

6. Remove the nuts securing the heat exchanger baffles retention

strip and remove strip.Withdraw the baffles.

7. Brush through heat exchanger tubes and remove loose material

using a vacuum cleaner. Remove any loose material from the
base of the combustion chamber, working through the burner port.

8. Reassemble all components in reverse order. Inspect all

gaskets and replace if necessary.

7.4 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 damaged 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.

7.5.2 Gas Controls Assembly

7.5.2.1 CA-G 100, 150

7.5.2.1.1 Gas Valve Coil.

1. To fit a new valve operating coil remove the electrical supply
plug, release the securing nut on top of the valve stem and
remove the nut and washer. Lift of the faulty coil and fit the new
coil in reverse order.

7.5.2.1.2 Block Valve Assemby.

1. Remove the electrical supply plug.

2. Release the unions on the connections at each end of the
assemby and remove complete assembly. Fit new assembly in
reverse order ensuring the valve assembly is correctly
orientated for the direction of gas flow.

7.5.2.2 CA-G 200, 300

7.5.2.2.1 Block Valve Assembly.

1. Release the union on the gas service valve

2. Remove the electrical connections to the valve assembly.

3. Release the socket head cap screws securing the connection
flanges to the main gas block valve and remove the block. Fit
new assembly in reverse order ensuring the valve assembly is
correctly orientated for the direction of gas flow.

7.5.2.3 CA-G 400 - 2000

1. Release the union on the gas service valve

2. Remove the electrical connections to the valve assembly.

3. Release the unions on the connections at each end of the start
gas block valve assemby and remove complete assembly.

4. Release the socket head cap screws securing the connection
flanges to the main gas block valve and remove the block. Fit
new assembly in reverse order ensuring the valve assembly is
correctly orientated for the direction of gas flow.

7.5.3 Main Fan Motor(s)

7.5.3.1. CA-G100 - CA-G400

Note: These heaters are fitted with direct drive fan units that
have an integral fan motor. The fan and motor must be ex­changed as complete unit.

7.5.3.2 CA-G 500 - 2000

1. Release the motor mounting plate securing screws and then
release the belt tension by turning the tension adjustment
screw clockwise. Remove the fan belts.

2.Disconnect the electrical connections from the motor and
remove the motor. If required remove the motor pulley and fit
same to the new motor.

3. Fit new motor and reassemble in reverse order.

4. Apply belt tension until a 12mm-15mm deflection is obtained
when the centre of the belt is firmly depressed. See Figure

below.

Fig 3 Belt Tension Adjustment

12mm - 15mm

7.5 Replacement of Faulty Components

7.5.1. Burner Components

1. Refer to the burner supplement supplied with the heater.

12

Supplied By www.heating spares.co Tel. [phone]

7.5.4 Main Air Fan(s)

CAUTION

DO NOT ROTATE - HOLD

DIAL WHEN SETTING POINTERS

2

0

4

0

6

0

8

0

1

0

0

1

2

0

F

A

N

L

I

M

I

T

Note: On 3ph heaters 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 necessary to remove one or more of the fans for
cleaning proceed as follows.

7.5.4.1. CA G100 - CA G400

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, the secure the fan to the fan shroud.

3. Withdraw the fan from the slide rails.

4. Reassemble in reverse order.

7.5.4.2. CA-G 500 - CA-G 2000

Note: These units are fitted with belt driven main air fans.

1. Release the motor mounting plate securing screws and then
remove the belt tension by turning the tension adjustment screw
anticlockwise. Remove the fan belts.

2. Remove the screws securing the fan mounting feet to theheater
framework and remove the fan. It may be necessary to re­orientate 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.

3. Fit new fans and reassemble in reverse order.

4. Retension fan belts See section 7.4.4.2

7.5.5 Fan and Limit Thermostats

7.5.5.1 CA-G 100 - CA-G 400 - Fan / Limit
Thermostat - Honeywell L4064N

1. Release the single screw securing the fan and limit thermostat

cover and remove cover by pulling forward.

2. Release wiring from clamp terminals by pushing 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 refering to the heater

wiring diagram to ensure correct wiring location.
Important:As supplied by the Manufacturer this fan/limit ther­mostat is fitted with a brass jumper between the bottom fan
terminal and the bottom limit terminal (situated in the slot
between the two terminals). This MUST be removed, by using
a pair of thin nose pliers, before the replacement thermostat is
installed.

5. Ensure that the fan and limit settings are as follows:­Fan ON 50°C
Fan OFF 30°C
Limit 110°C

Fig 4 Honeywell L4064N

Set Point Dial

Fan Circuit

Summer /
Winter
Switch

Fan Circuit

Jumper location

Limit Circuit

Limit Circuit

Limit Reset

7.5.5.2 CA-G 500 - CA-G 2000 - Fan / Limit
Thermostat - White Rodgers 5F464

1. Release the single screw securing the fan and limit thermostat

cover and remove cover by pulling forward.

2. Release wiring from screw terminals.

3.Remove the head base or a top side panel from the heater to

gain access to the heat exchanger and release the thermostat
sensing phial from its holder on top of the heat exchanger.

3. Remove the 2 screws securing the thermostat to the heater

panel and withdraw thermostat and phial.

4. Reassemble new unit in reverse order refering to the heater

wiring diagram to ensure correct wiring location.

5. Esure that the fan and limit settings are as follows:­Fan ON 50°C
Fan OFF 30°C
Limit 100°C

Fig 5 White Rodgers 5F464

Limit Circuit

Limit Settings

°C

80 90 100 110

LIMIT FAN

Fan Settings

70

50

30

Fan Circuit

13

Summer / Winter Switch

Supplied By www.heating spares.co Tel. [phone]

7.5.5.3 CA-G 500 - CA-G 2000 - High Limit
Thermostat.

1. Release the two screws securing the limit thermostat housing

cover and remove cover by pulling forward.

2. Release the thermostat from the front cover, two screws

3. Pull off wiring connectors at the rear of the thermostat.

4.Remove the head base or a top side panel from the heater to

gain access to the heat exchanger and release the thermostat
sensing phial from its holder on top of the heat exchanger and
withdraw thermostat and phial.

5. Reassemble new unit in reverse order refering to the heater

wiring diagram to ensure correct wiring location.

6. Ensure that the setting is as follows:­Limit 100°C

8. Connections to Powrmatic External

Controls

8.1 Powrtrol

CA-G connect to Powrtrol
Terminals Terminals

11

85
96

8.2 Eurotrol

CA-G connect to Eurotrol
Terminals Terminals

1 CTRL CCT

2 CTRL CCT
8 FAN CCT
9 FAN CCT

9. Fault Finding

Refer also to the burner supplement supplied with the heater

Fault

Main burner will not light

Main burner lights, but goes
out before main fan comes on.

Cause

Electrical

Electrical

1. Check electrical and gas supplies are ON.

2. Check controls are ON or calling for heat.

1. Unit goes out on high limit ­a. Check fan thermostat setting - See Section 7.6.5.
b. Faulty fan thermostat - change
c. Check limit thermostat setting - See Section 7.6.5.
d. Faulty limit thermostat - change.

2. Faulty fan assembly - change.

3. (Ducted Units Only) -fan motor out on thermal overload. - Check running amps.
See table 4.- check duct resistance See Table 5.

Action

Main fan runs continuously

Main fan fails to run

Electrical

Electrical

1. Summer/Winter switch set to Summer.

2. Fan thermostat set too low - check setting See Section 7.6.5

3. Faulty fan thermostat - change

1. Fan motor or capacitor failed - replace.

2. Fan thermostat faulty - replace.

3. Fan contactor failed - replace (3ph units)

14

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10. Short List of Parts

Refer also to the burner supplement supplied with the heater.
Refer to Powrmatic Ltd for the details of any parts not listed here.

ITEM

Johnson Controls GM-7742-3503 - ½"BSP.
Johnson Controls GM-2540-2000 - ¾"BSP.
Johnson Controls GM-2040-2000 - 1"BSP.
Johnson Controls GM-4540-3000 - 1½"BSP.
Thermostat - Fan / Limit Honeywell L4064
Thermostat - Fan / Limit White Rogers 5F46-4
Thermostat - Limit Landis & Gyr RAK 21.4/2926
Contactor - Danfoss CI 9
Overload - Danfoss TI 16 (0.6 - 0.92A)
Overload - Danfoss TI 16 (1.2 - 1.9A)
Overload - Danfoss TI 16 (2.7 - 4.2A)
Overload - Danfoss TI 16 (4.0 - 6.0A)
Overload - Danfoss TI 16 (8.0 - 12.0A)
Overload - Danfoss TI 16 (11.0 - 16.0A)
Y - D Starter - Danfoss SDI 12 047 L1280-38
Pressure Relief Door Gasket - 114mm dia.
Pressure Relief Door Gasket - 95mm dia.
Pressure Relief Door Gasket - 166mm x 166mm.
Burner Gasket - Nu-Way PCGS 2/3/5.
Burner Gasket - Nu-Way PCGS 8/13.
Burner Gasket - Nu-Way PCGS 25
Burner Gasket - Riello GS5.
Burner Gasket - Riello GS10.
Burner Gasket - Riello GS20.
Burner Gasket - Riello Gas 3
Burner Gasket - Riello Gas 5

APPLICATION

100,150, 400 - 2000
200 - 600
700 - 800
1000 - 2000
100 - 300
400 - 2000
400 - 2000
All
100 (3ph)
150 (3ph), 200 (3ph)
300 (3ph),400
500 - 800, 1500
1000
2000
1000LHP, 1500, 2000
ALL
ALL
ALL
100 - 500
600 -1000
1500 - 2000
100
150 - 300
400 - 600
700 - 1000
1500,2000

PART NUMBER

141379957
141379954
141379955
141379967
143000303
143000331
142403597
143000608
143056103
143000861
143000706
143000707
143000770
143000850
143070226
142202110
142202257
142202310
144704004
144704015
144704026
141937080
141930806
142931252
142931240
142931245

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