Powrmatic CP series User, Installation And Service Manual

CP Range

Users, Installation & Servicing Instructions

Gas & Oil Fired Heaters

CE

WARNING: THIS APPLIANCE MUST BE EARTHED

CP(2007) Range Issue 3.5 July 2009

TESTED

Full mechanical, construction, assembly and electrical sequence check

Full functional test in accordance with Quality System Procedures

Heater Model

Heater Serial No.

Fuel Type

Dear Customer

This is to certify that this appliance is guaranteed for two years including parts and
labour from the date of original commissioning.

The heat exchanger, where fitted, is guaranteed (parts only) for a further eight years,
chargeable on a sliding scale basis, price relative to age.

To make a claim

In the first instance you must contact your appliance supplier, or installer and
provide:-

1. The appliance type and serial number.

2. The original commissioning documentation.

3. As much detail as possible on the fault.
Your supplier, or installer will then contact Powrmatic to make a guarantee claim
on your behalf.

Conditions of Guarantee

1. The appliance must have been installed by a competent recognised installer,
and in accordance with the manufacturers instructions, building regulations and
local regulations.

2. The appliance has been professionally commissioned.

3. The appliance has been maintained on a yearly basis by a competent servicing

company.

4. The appliance has been used in accordance with the manufacturers instructions.

5. The correct specification fuel has been used

6. No unauthorised repairs or modifications have been made.

7. Powrmatic General Conditions of Sale have been observed.

8. Except for the obligation of Powrmatic Ltd to perform warranty repairs during
the guarantee period, Powrmatic will not be liable in respect of any claim for
direct or indirect consequential losses, including loss of profits or increased costs
arising from loss of use of the appliance, or any event arising there from.

Exclusions

1. Gaskets and fan belts are not included in the guarantee

Important: This certificate must

be kept with the appliance

Certificate of Guarantee

Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS

tel: [phone] fax: [phone]

web: www.powrmatic.co.uk

1. Checks before lighting the Air Heater

The following checks should be made before lighting the heater(s)
a) Ensure the electrical supply to the heater is switched OFF.
b) Check that all warm air delivery outlets are open.

c) Check that the thermostat is set at MAX.
d) Check that the clock control is set to an ON period.

e) Check that any other controls are calling for heat.
f) Ensure the Summer/Winter switch (fitted on the Powrtrol) is

in the Winter position.
g) Check that the overheat reset button has not operated.

2. Lighting the Air Heater

2.1 Gas-fired Heaters

1. Switch on the electrical supply at the isolator and the burner
start-up sequence will commence. The burner air fan will run
and after a pre purge period of approximately 30 seconds the
ignition spark will be generated.

CP 100 - 300
The main gas valves will open and the main burner will be

established
CP 400 - 2000
The start gas valves will be opened and a start gas flame

established. When a start gas flame is established the main gas
valves will be energized and the start gas flame will expand to
main flame.

NOTE: If the main burner or a start gas flame fails to establish
the burner will go to lockout and the lockout indicator / reset
button on the burner control box will be illuminated. To restart
the burner push the lockout reset button. Additional, more easily
accessible, controls may be fitted that mimic the lockout indicator
and reset button functions.

If the unit will not light after four or five attempts then shut
down the unit and call in a service engineer.

2.2 Oil-fired Heaters

NOTE: If it is not possible to light the heater after 2/3 attempts
contact the local service company.

1. Switch on the electrical supply at the isolator and the burner
start-up sequence will commence. The burner air fan will run
and after a pre purge period of approximately 30 seconds the
ignition spark will be generated and the oil valve opened.

The main burner will then start.
NOTE: If the burner fails to light it will go to lockout and the

lockout indicator / reset button on the burner control box will
be illuminated. To restart the burner push the lockout reset
button.

3. To Shut Down the Air Heater

3.1 For Short Periods:
Turn the room thermostat to the OFF or lowest setting.

3.2 For Long Periods:
Turn the room thermostat to the OFF or lowest setting.
Wait approximately 4-5 minutes for the main air fan of the
heater to stop running and the turn off the gas or oil supplies
and electric supplies to the heater.

4. Description of Operation

Important: All heaters must be controlled by the fitted external
controls and not by use of the main switch in the electrical
supply to the heater.

The burner start up sequence will commence when the controls
e.g. Timeclock, room thermostat etc. call for heat. The burner
air fan will run and after a pre purge period the burner will light.

Approximately 2/3 minutes after the burner lights the heater fan

Users Instructions

will automatically start. When the external controls are satisfied
the burner will be turned off and approximately 4/5 minutes
later the heater fan will automatically stop.

4.1 Summer / Winter Modes

Certain types of external controls will provide for two modes
of operation i.e.

Summer: The heater fan alone will run at the dictate of the

external controls to provide air movement.

Winter: The heater will operate normally.

5. Fan and Limit Control

The fan and limit controls are mounted towards the top of the
air heater upper front panel.

5.1 CP 100 - 1000

i) Main Air Fan MAN / Auto
When the white button (Refer to Figure below) is pushed in

the fan will run continuously i.e not controlled by any external
controls e.g. Timeclock. When the white button is pulled out
the fan will start and stop automatically in conjunction with
the burner. See Section 4.

ii) Limit Thermostat Reset
In the event of a fault that causes the temperature of the air

leaving the air heater to rise significantly e.g. Blocked air inlets,
the limit thermostat will operate to shut down the burner.
Remove the cause of the fault, wait 10 minutes and then reset
the thermostat by pushing the red reset button (Refer to Figure
below) .If the limit thermostat continues to operate turn off the
air heater and call a service engineer.

PUSH TO

RESET

PUSH MAN

PULL AUTO

Honeywell

Red

reset

button

Fig 1. Limit Thermostat CP 100 - 1000

White

Fan

button

6. Maintenance

Regular servicing is essential to maintain efficient, reliable and
safe operation of the heater. Users are strongly recommended
to have the heater serviced at least annually and preferably at
the end of the heating season.

7. IMPORTANT

Free access must be maintained to and around the heater for
servicing purposes and the air supply to the heater must not be
restricted in any way. Combustible materials must not be stored
adjacent to the heater.

All Powrmatic heaters use gas and electricity to power them,
they may also contain moving parts such as pulley belts. It
would be hazardous to tamper with or attempt to service unless
you are a competent person in the field of Gas and Electrical
work.

If you have any safety questions reference the servicing and
installation of any of our heaters please do not hesitate to contact
our head office for expert advice.

Your safety is paramount to us.

For gas fired heaters:

If at any time a gas leak is suspected turn OFF the gas supply

- DO NOT USE A NAKED FLAME - and contact the local gas
undertaking immediately.

Gas Safety (Installation & Use) Regulations

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.

**

An approved class of person listed on the gas register.

Section Title Page

1. Introduction 4

2. Technical data 5

3. General requirements 9

4. Installation of air heater(s) 10

5. Commissioning & testing 13

6. Servicing 15

7. Fault finding 17

8. Short list of parts 17
Appendix A 18

Table Title Page

1. Dimensions 7

2. Specifications 7

3. Electrical Data 7

4.1 Burner Pressures for Natural Gas - Groupe H  Type G20 8

4.2 Burner Pressures for Propane  Type G31 8

5. Pump Pressures for 35sec fuel oil 8

Diagram Title Page

1. Minimum clearance dimensions 10

2. Dungs valves - pressure adjustment 13

3. Fan belt tension setting 15

4. Thermostat Fan / Limit - Honeywell L4064N 16

5. Thermostat Fan / Limit - White Rodgers 5F464 16

Index

3

Installation & Servicing Instructions

1. INTRODUCTION

The Powrmatic CP range of closed flue, fanned circulation air
heaters cover a heat output range of 29.3 kW to 586.1 kW and
are intended primarily for heating commercial or industrial
premises. They are fitted with either a gas fired forced draught
burner or a pressure jet oil fired burner.
Gas fired units are certified for use on Natural Gas, Group H

- G20, Group L - G25 and Propane - G31.
Oil fired units are supplied as standard for use with 35sec fuel

and can be supplied for use with 28sec fuel as an option.
CP heaters have a centrifugal fan assembly fitted upstream of

the combustion chamber / heat exchanger assembly to circulate
the air being heated.

CP heaters are available in three styles:

Standard Style

Suitable for internal applications only and available in /UF,
/UD, /HD, /HF, /CF and /CD variants (see below). /UF and /UD
models are floor standing, /HD, /HF, are horizontally mounted
on purpose design supports. /CD models can be plinth mounted
at floor level. /CF and /CD models can be mounted at high level
on purpose design supports.

CP/NCA Style

Suitable for internal applications only and having an extended
casing that encloses the burner. Available in /UF and /UD
variants only(see below).

CP/EA Style

Casing is extended to enclose the burner. The heater is fully
weatherproof and designed for external applications only.
Available in /TD, /HD, /RT and /SD variants (see below).

Variant types are:­/UF - Upright heater with free blowing rotatable heads.
/UD - Upright heater with outlet duct spigot (inlet duct spigot

optional).

/HF - Horizontal heater with free blowing rotatable heads.
/HD - Horizontal heater with outlet duct spigot (inlet duct spigot

optional).

/CF - Counterflow heater with free blowing rotatable heads.
/CD - Counterflow heater with outlet duct spigot (inlet duct spigot

optional).
/TD - Rooftop heater with top outlet duct spigot (inlet duct spigot

optional).

/RT - Rooftop heater with outlet duct spigot on the underside

(inlet duct spigot optional).
/SD - Upright heater with side outlet duct spigot (inlet duct spigot
optional).

Other options include High/Low or modulating burners, uprated
main fan motors, flue support bracket, deep V filters, flat panel
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.

For gas fired heaters

Gas Safety (Installation & Use) Regulations

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.

* *

An approved class of person listed on the gas register.

4

Installation & Servicing Instructions