Powrmatic CPx30, CPx300 User, Installation And Servicing Instructions

Issue 2.1 June 2014

WARNING: THIS APPLIANCE MUST BE EARTHED

GB & IE H E A T I N G / / V E N T I L A T I O N / / A I R C O N D I T I O N I N G

CPx Gas or Oil Cabinet Heater Range

Industrial & Commercial Heating Systems.

Users, Installation and Servicing Instructions

Gas & Oil Fired Cabinet Heaters

CPx30 - CPx300

(L4064B)

Page 2 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

powrmatic

Certificate of Guarantee

Dear Customer

This is to certify that this heater is guaranteed for two years parts and one year labour from
the date of original commissioning. The heater must be commissioned within 4 weeks of
installation.

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

2. The heater has been professionally commissioned, within 4 weeks of installation, and a
copy of the Commissioning Sheet returned to Powrmatic.

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

4. The heater 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 heater, or any event arising there from.

Exclusions

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

----------------------------------------------------

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

Tel:[phone] Fax: [phone]

Web: www.powrmatic.co.uk e-mail [e-mail]

Important: This certicate must

be kept with the appliance

Failure to provide a copy of the installtion sheet invalidates the destratification fan warrantee

Installer

Date :_____________ Signed ____________________________________________Installer

Commissioned

Date :_____________ Signed _______________________________Commissioning Engineer

Dear Customer - thank you for choosing Powrmac.

We appreciate you buying one of our high quality products and know that you have made the best

choice. By choosing Powrmac, you are invesng in UK manufacturing & its workforce. We pride
ourselves by manufacturing products that provide clean, comfortable and safe working environ­ments worldwide together with the personal & professional service and back-up you deserve. If you
have any quesons or concerns regarding this product, please contact our Technical Support Team by
calling 01460 53535.

Users, Installaon and Servicing Instrucons

CONTENTS

Title Secon Contents Page

User Instrucons 4

Pre Installaon

1.1 Introducon 6

1.2 General Requirements 7

1.3 Size Data 8

Installaon

2.1 Fing the unit 11

2.2 Fing the Flue and Combuson and 15
Venlaon Air Requirements

2.3 Basic Unit 16

2.4 Electrical Cable Instrallaon 16

2.5 Commissioning and Tesng 17

Data

3.1 Technical Data 21

3.2 Short List of Parts 23

Servicing

4.1 Servicing 23

4.2 Fault finding 26

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 3

Users Instructions

A) Checks before lighting the Air
Heater

The following checks must 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 and,
if there is a Summer/Winter mode, it is set to Winter.
f) Check that the overheat reset button has not operated.

B) Lighting the Air Heater

1) Gas-fired Heaters

1. Switch on the electrical supply at the isolator.

2. The burner air fan will run and after a pre purge period
of approximately 30 seconds the ignition spark will be
generated.

CPx 30 - 90
The main gas valves will open and the main burner will be
established

CPx 120 - 300
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) 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.

2. 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 fire.

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.

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

C) To Shut Down the Air Heater

1) For Short Periods:

Turn the room thermostat to the OFF or lowest setting.

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.

D) 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 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.

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.

Page 4 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

E) Fan and Limit Control

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

i) Main Air Fan MAN / Auto

When the white button (Refer to Figure 1 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

This operates if high temperatures within the heater are
detected, the burners are turned off and a red indicator
light on the front of the heater is illuminated. The fault
condition must be identified and rectified and the thermo­stat manually reset.
When the unit has cooled push the reset switch on the
front of the heater to reset the limit thermostat interlock
relay, the red indicator light will go out and the unit is oper­ational again.

Note: The limit thermostat(s) can only be reset
once the unit has cooled down. Unless the cause
of the fault condition is readily obvious, for exam­ple a power cut whilst the heater was
operating, a service engineer should be contact­ed.

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.

F) 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.

G) 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, or oil, 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 only:

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 latest edition of
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.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 5

PUSH MAN

PULL AUTO

Honeywell

Fig 1. Limit Thermostat

White

Fan

button

1.1 Introduction

The Powrmatic CPx range of closed flue, fanned circula­tion air heaters cover a heat output range of 30 kW to
290kW and are intended primarily for heating commercial
or industrial premises.

They are B23 type appliances fitted with either a gas fired
forced draught burner or a pressure jet oil fired burner.

Fuel Types

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.
In accordance with guidelines from our burner supplier,
Riello, the burners fitted to Powrmatic oil-fired heaters are
suitable for fuels with a bio content of up to 10% only.
For fuels with a bio content of more than 10% please
consult our Technical Department.

CPx heaters have a centrifugal fan assembly fitted
upstream of the combustion chamber / heat exchanger
assembly to circulate the air being heated.

CPx 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.

CPx/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).

CPx/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.

IMPORTANT

Service and Maintenance Engineers shall ensure
that replacement items are fitted, adjusted and
set in accordance with the data and detail set out
in these instructions.
If in doubt consult Powrmatic Technical Depart­ment.

For gas fired heaters only.

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 latest edition of
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.

Page 6 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

1.2 General Requirements

1.2.1 Gas Fired Heaters

1.2.1.1 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 also be in accordance with any relevant require­ments of the local gas region, local authority and fire
authority and the relevant recommendations of the follow­ing documents.

Institution of Gas Engineers & Managers
IGE/UP/1 (Ed.2) Strength and tightness testing and purg-

ing of industrial and commercial gas installations.

IGE/UP/1A (Ed.2) Soundness testing and direct purging
of small low pressure industrial and commercial gas
installations.

IGE/UP/1B (Ed.2) Tightness testing and direct purging of
small Natural Gas installations.

IGE/UP/2 Gas installation pipework, boosters and com­pressors on industrial and commercial premises.

IGE/UP/4 (Ed.2) Commissioning of gas fired plant on
industrial and commercial premises.

IGE/UP/10 (Ed.3) Installation gas appliances in industrial
and commercial premises.

British Standards & Codes of Practice

BS 9999 Code of practice for fire safety in the design,

management and use of buildings

BS 6230: 2011 Installation of Gas Fired Forced Convec­tion Air Heaters for Commercial and Industrial Space
Heating.

Those appliances having a gross input rating not exceed­ing 60kW viz. CPxG30 - 45 inclusive and installed so as to
take their combustion air from within the building must be
installed in accordance with the relevant recommenda­tions of the following document.

BS 5440 Flues and Air Supply for gas appliances of rated
input not exceeding 60kW (1st and 2nd family gases),
Part 2 – Air Supply
Reference should also be made to:-

BS 5864. Installation and maintenance of gas-fired ducted
air heaters of rated heat input not exceeding 70 kW net
(2nd and 3rd family gases).

1.2.1.2 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.

1.2.1.3 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.

1.2.1.4. Installation Pipes

Installation pipes should be fitted in accordance with
IGE/UP/2. 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.

1.2.2 Oil Fired Heaters

1.2.2.1 Related Documents

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

OFTEC Technical Book 3: Domestic & Commercial
requirements for oil storage and supply equipment.
OFTEC Technical Book 4: Oil fired appliances & system
installation requirements.
OFTEC Easy Guides to non domestic oil feed pipes and
oil storage.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 7

Page 8 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

1.3 Size Data

CPx UD/UF Upright Free Blowing and Ducted (30-300)

Model

A
B

C

D
E

All
All
All
All
All

mm
mm
mm

mm Ø

mm

732
669

1767

125
150

732
669

1767

125
150

927
744

1895

150
150

927
744

1895

150
150

1200

904

2149

150
150

1200

904

2149

175
170

1399

904

2265

175
170

1399

904

2265

175
170

30 45 60 90 120 150 175 200

1599
1104
2265

200
182

1599
1104
2265

200
182

250

300

F

All mm 1535 1535 1661 1661 1923 1923 2021 2021 2021 2021

G

All mm 864 864 944 944 1122 1122 1132 1132 1122 1122

H

Gas mm 295 295 346 346 389 389 389 610 610 610

Oil mm 236 236 261 261 295 295 295 473 473 473

J

All mm 238 286 286 340 340 340 400 442 558 558

J1

All mm n/a n/a 581 672 672 672 788 875 1042 1042

K

All mm 180 234 229 281 281 281 333 381 431 431

L

Duct mm 632 632 824 824 1100 1100 1299 1299 1499 1499

M

Spigot mm 569 569 644 644 804 804 804 804 1004 1004

Head Plan

1 1 2 2 3 3 3 3 4 4

Notes:- Flue Tee provided as standard

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 9

CPx HF/HD Horizontal Free Blowing and Ducted (30-300)

Notes:­FlueTee provided as standard.
Screened air intake (SAI) tted as standard on HF models Duct spigot option available.
Direction of airow to be specied at time of order. Left to Righ ( L -R when looking at the burner) airow shown above.

Model

A

B
C
D

E

All
All
All
All
All

mm
mm
mm

mm Ø

mm

732
669

1767

125
150

732
669

1767

125
150

927
744

1895

150
150

927
744

1895

150
150

1200

904

2151

150
150

1200

904

2151

175
170

1399

904

2265

175
170

1399

904

2265

175
170

30 45 60 90 120 150 175 200

1599
1104
2265

200
182

1599
1104
2265

200
182

250

300

F

All mm 1535 1535 1661 1661 1923 1923 2021 2021 2021 2021

G

All mm 864 864 944 944 1122 1122 1122 1122 1122 1122

H

Gas mm 295 295 346 346 389 389 389 610 610 610

Oil mm 236 236 261 261 295 295 295 473 473 473

J

All mm 230 230 190 190 275 297 297 297 367 367

L

Duct mm 632 632 824 824 1100 1100 1299 1299 1499 1499

M

Spigot mm 569 569 644 644 804 804 804 804 1004 1004

125 125 125 125 150 150 150 150 150 150

Head Plan

1 1 2 2 3 3 3 3 4 4

N

All

mm

Page 10 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

CPx - EA External Cabinet Heaters (30-300)

Notes:­Direction of airow to be specied at time of order. Left to Right (L-R when looking at the burner) airow shown above.
Inlet and Outlet duct spigots have the same dimensions.
Primary ue length, cowl and ashing provided as standard.

Model

A

B

C
D

All
All
All
All

mm
mm
mm

mm Ø

1184

669

1767

125

1184

669

1767

125

1379

744

1895

150

1379

744

1895

150

1692

904

2149

150

1692

904

2149

175

1891

904

2265

175

1891

904

2265

175

30 45 60 90 120 150 175 200

2280
1104
2265

200

2280
1104
2265

200

250

300

F

All mm 1535 1535 1661 1661 1923 1923 2021 2021 2021 2021

L

Outlet Duct mm 632 632 824 824 1100 1100 1299 1299 1499 1499

M

Spigot mm 569 569 644 644 804 804 804 804 1004 1004

125 125 125 125 150 150 150 150 150 150

N

All

mm

L

Inlet Duct mm 632 632 824 824 1100 1100 1299 1299 1499 1499

M

Spigot mm 569 569 644 644 804 804 804 804 1004 1004

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 11

2.1 Fitting the unit

2.1.1 General

Before installation, check that the local distribution condi­tions, fuel specification, and adjustment of the appliance
(see data plate) are compatible.
Important:
Copper Sulphide / ‘Black Dust’
In some areas of the UK, particularly Northern Ireland,
problems have been experienced with copper sulphide
(more commonly referred to as ‘Black Dust’) forming on
the inner surfaces of copper gas supply pipework. This
dust can enter the gas stream and may lead to blockages
of valves, filters and injectors.
If this heater is being installed in an area where ‘Black
Dust’ is known to be a problem, and copper gas supply
pipework is used, it is recommended that a filter having a
stainless steel 50 micron mesh and suitable for Natural
Gas is fitted at the inlet to the appliance immediately
downstream of the main appliance isolation valve. The
end user should be advised that the filter will require
periodic cleaning or replacement at least once per year,
during the annual service, or more often if the problem is
severe.

2.1.2 Location

The location chosen for the air heater must permit:

- the provision of a satisfactory flue system and an
adequate air supply.

- 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 atmosphere
is corrosive or salty, and they are not suitable for outdoor
use unless the CPx/EA style is specified. CPx/EA heaters
must be installed on a plinth such that there is a minimum
distance of 0.5m between ground level and the lowest
point of any air inlet grilles.
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.
CPx heaters are for normal operation within an ambient
temperature range of -10 to 25°C.
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, particu-

larly where special risks are involved such as areas where
petrol vehicles are housed, where cellulose spraying is
carried out, in wood working departments etc.

* Head plan 2 can not be inverted, as one head needs to be placed over the limit stat.

Page 12 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

larly where special risks are involved such as areas where
petrol vehicles are housed, where cellulose spraying is
carried out, in wood working departments etc.

IMPORTANT:

Heaters shall not be installed in:­a) Those parts of spaces within buildings that
have been classified as hazardous areas as
defined in BS EN 60079-14.
b) Where there is a foreseeable risk of flammable
particles or gases 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 both air sources
are from an uncontaminated source, preferably
from outside the building. It may also be neces­sary to purge the air heater before the burner is
allowed to fire. In certain situations where only
airborne particles are present it may suffice to fit
filters on the main air inlet duct of the heater.
Advice in these instances must be obtained from
Powrmatic Ltd.
c) In areas subjected to significant negative pres­sures due to extract systems.

2.1.3 Installing the Air Heater

If necessary consideration should be given to mounting
the heater on resilient pads, or equivalent, to minimize
transfer of noise and vibration to the structure of the build­ing.
Floor mounted heaters must be installed on a level
noncombustible surface.
Heaters mounted at high level must be supported on a
purpose designed platform or framework that is suspend­ed from vertical drop rods, chains or straps or mounted on
specifically designed cantilever brackets from a non-com­bustible wall. The method of installation support must be
capable of adequately supporting the weight of the unit
(See Table 2, Page 21) and any ancillary equipment.
Before installing the heater the existing structure must be
inspected to ensure it is suitable. All supports should be
protected against the effects of rust or corrosion.
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 (A)
To the rear 1.0m
To the side having louvred lower panels 1.0m
To the side having blank lower panels (see below) 0.15m
Above the heater 1.0m

Fig 1 Minimum clearance distance

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 13

Important:

CPx 250 & CPx 300 heaters have louvred lower
panels on both sides. The minimum clearance of

0.15m is increased to 0.5m.

Important:

Smaller heaters are supplied with one blank side
panel and one louvred side panel. If the heater is
installed against a wall ensure that the blank
panel is facing the wall, interchanging the two side
panels if necessary.
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.

If the method of mounting allows for any move­ment of the heater it is essential that all gas, duct,
and electrical connections to the heater are made
with flexible connections to maintain continuity of
connection.

2.1.4 Combustion & Ventilation Air
Supply

There shall be provision for a supply of air for combustion
and, in the case of heaters installed in an enclosure or
plant room, for ventilation.
Actual values relating to the details below

1) Installation in the heated space
In buildings with a design air change rate of 0.5 /h or great­er, additional natural or mechanical ventilation is not
necessary. In buildings not having a design air change
rate of 0.5 /h the following apply.

Natural Ventilation
Grilles having a free area of at least 2cm² per kW of rated
heat input shall be provided at low level i.e. below the level
of the heater flue connection.

Mechanical Ventilation
Must ensure that the space air change rate is at least

0.5/h, must be of the ‘input’ type and interlocked to ensure
the heaters cannot work if the input system is not working.

CPx Combustion & Ventilation Air Supply

Type B23 Installation
These refer to section 2.1.4. of the instructions

Air vents shall be permanently open.
Figures in column 1 are for heaters installed in the space they are heating.
Figures in column 2 are for heaters installed in a plant room, ventilation to outside air.
Figures in column 3 are for heaters installed in a enclosures, ventilation to outside air.
In all cases figures are per heater installed.
For multi heaters installations the appropriate values for each heater must be added together.
1 2 3
In the In a plant room In an enclosure
Space
CPx Input Low Low High Low High
kW Level Level Level Level Level
Grille Grille Grille Grille Grille
Free Free Free Free Free
Area Area Area Area Area
cm2 cm2 cm2 cm2 cm

2

30 32.29 64.6 129.2 64.6 322.9 161.5
45 48.97 97.9 195.9 97.9 489.7 244.8
60 64.62 129.2 258.5 129.6 646.2 323.1
90 98.31 196.6 393.2 196.6 983.1 491.5
120 127.43 254.9 509.7 254.9 1274.3 637.1
150 162.90 325.8 651.6 325.8 1629.0 814.5
175 190.07 380.1 760.3 380.1 1900.7 950.4
200 215.87 431.7 863.5 431.7 2158.7 1079.3
250 269.86 539.7 1079.4 539.7 2698.6 1349.3
300 316.25 632.5 1265.0 632.5 3162.5 1581.2

Page 14 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

2) Installation in plant rooms or enclosures
There must be permanent air vents communicating direct­ly with the outside air, at high level and at low level.

Plant Rooms
Low level (inlet) 4cm²/kw of total rated net heat input
High level (outlet) 2cm²/kw of total rated net heat input

Enclosures
Low level (inlet) 10cm²/kw of total rated net heat input
High level (outlet) 5cm²/kw of total rated net heat input

Mechanical Ventilation
The minimum flow rate of ventilation shall be 4.14m³/h per
kilowatt of total rated heat input.

2.1.5. Gas Connection (if applicable)

• A servicing valve and union must be fitted at the gas inlet

to the heater to facilitate servicing.

• The gas supply to the air heater must be completed in

solid pipe work and be adequately supported.

• Heaters suspended by drop rods, straps or chains must

have a flexible connection as the final link between the
gas supply pipe work and the heater. Sufficient slack must
be left in the connection to take account of normal move­ment of the heater.

Warning:
When completing the final gas connection to the
heater do not place undue strain on the gas pipe
work of the heater.

2.1.6. Oil Connection (if applicable)

Refer to the supplied burner installation instructions for
details regarding oil supply options.

2.1.7. Air Distribution System

For free-blowing units used in buildings having a low heat
loss i.e. 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.

Care should be taken to avoid impeding the heater 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.

CPx*/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.

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.

Where inter-joist 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, into and out of the
plant room to avoid interference with the operation of the
heater from other equipment.

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 where there is any
possibility of pollution of the air by dust, shavings etc.,
precautions must be taken to prevent contamination.

If necessary suitable barrier rails should be provided to
prevent any combustible material being placed within
900mm of the outlets.

Joints and seams of supply ducts and fittings must be
securely fastened and made airtight.

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 an adequate clearance 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.

2.1.8 Room Thermostat Siting

If a remote room thermostat, or controller with an integral
sensor, is used it 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
floor level.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 15

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
floor level.

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.

2.2 Fitting the Flue, Combustion and
Ventilation Air Requirements

A single wall tee piece is supplied with each heater and
must be fitted to the flue outlet socket on the heater. A
closed chimney system that conforms to the require­ments of EN1856-1 and has a designation appropriate to
the application must be connected to the outlet of this
tee. The cross sectional area of the chimney serving the
appliance must be not less than the area of the flue
outlet of the air heater. The chimney must have a
minimum height, from the heater to the flue terminal, of
2m. Horizontal runs of flue must be minimised but where
they are unavoidable the ratio of vertical to horizontal
flue should be not less than 3:1.

If necessary a single offset using two 45° bends can be
included to avoid obstructions. The minimum equivalent
resistance of the flue system should not be less than

0.0mb, the maximum not greater than 0.5mb. Details of
how to calculate the resistance of the flue to be installed
are given in Appendix A.

In order to minimise condensation the use of twin wall
chimney is recommended. With high efficiency heaters
some condensation in the chimney, particularly at the
terminal, is unavoidable and in addition there can also be
rain water ingress. Use of a chimney system having joint
seals will minimise any leakage from the flue system.
The heater tee is provided with a collection tray and the
outlet from this should be run to a drainage point e.g. a
gully. The condensation pipe from the collection tray to
the disposal point should be of non-corrodible material of
not less than 22mm (3/4") size.

Facilities should be made for disconnecting the chimney
pipe(s) from the air heater(s) for inspection and servicing
purposes.

The chimney outlet must be fitted with a terminal and
where the heater chimney is less than 200mm (8") in
diameter an approved terminal must be used.

The chimney must be supported independently of the air
heater.

The chimney must terminate in a freely exposed position
and must be situated so 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.

The chimney terminal must be installed not less than:

- 300mm below an opening e.g. window, air brick etc.

- 200mm below eaves or gutter.

- 300mm from an internal or external corner.

- 1200mm from a surface facing the terminal.

- 1500mm vertically from another terminal on the same
wall.

- 300mm horizontally from another terminal on the same
wall.

- 2000mm from ground level.

2.3 Basic Unit

Fan / Limit stat

Exhaust Flue

Burner

Data Plate

MC200 Controller

High Limit Reset

Electrical Connections
(behind cover)

2.4 Electrical Cable Installation

Electrical Connections

Wiring external to the air heater must be installed in accor­dance with the I.E.E. Regulations for Electrical Installations
and any local regulations which apply. Wiring should be
completed in exible 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 nal 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 exter­nal controls must be of an approved type.

Page 16 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

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 connect­ed 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)

Standard Uprated

Motor Motor
FUSE FUSE
MODEL PH RATING RATING
(A) (A)

CPx30 1 5 N/A
CPx45 1 7 N/A
CPx60 1 7 N/A
CPx90 1 7 N/A
CPx120 3 7 N/A
CPx150 3 7 10
CPx175 3 10 15
CPx200 3 10 15
CPx250 3 15 15
CPx300 3 15 15

2.5 Commissioning & Testing

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 recom­mendations of OFTEC.

2.5.4 Air Distribution System

The system should be checked to ensure that the instal­lation 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

2.5.5.1 Gas Fired Heaters

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.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 17

Page 18 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

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 pres­sure 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 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.

2.5.5.1.1 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 pres­sure 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 thermo­stat to call for heat or complete the external control circuit.

3. Turn ON the main electrical supply, press the limit inter­lock 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 measur­ing instrument.

2. Turn ON the main electricity supply, press the limit inter­lock 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 estab­lished.

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 neces­sary 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 measur­ing 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

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 19

2. Turn ON the main electrical supply, press the limit inter­lock 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 neces­sary 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 pres­sure 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 inter­lock relay reset switch and check that the burner fan
starts.

Page 20 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

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 unsuc­cessful 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 neces­sary 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 reten­tion and instruct the User in the efficient and safe opera­tion 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.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 21

3.1 Technical Data

Table 2. Specifications

Fan motor

Gas Oil

Model

Nom.
Input
(Nett)

Air

Volume

Standard

Motor

Uprated

Motor

Output

Maximum duct

resistant

Standard

Motor

Uprated

Motor

Kw m³/s pa Kw

Weight

Fuel

Connection

Size

Kg

CPx

CPx

/NCA

CPx

/EA

CPx120

R

c

¾

341130.4 120.0 2.3040 140 N/A 2.2 N/A

¼”

BSP

448 458

CPx300

315.2

R

c

1¼

556

290.0 5.7600 150 250 5.5 7.5

3

/

8”

BSP

TBA TBA

CPx60 65.2 60.0 1.1520 185 N/A 0.550 N/A R

c

¾

173

¼”

BSP

210 215

231 210 215

CPx90 90.097.8 1.7280 100 N/A 1.1 N/A R

c

¾ 241¼”

BSP

304 304

CPx150

163.0

150.0 2.8800 175 240 2.2 3.3 R

c

1¼ 386¼”

BSP

535 546

CPx175 190.2 175.0 3.3600 190 250 3.3 5.5 R

c

1¼

530

¼”

BSP

TBA TBA

CPx200

217.4

200.0 3.8400 100 200 4.0 5.5 R

c

1¼

530

¼”

BSP

TBA TBA

CPx250

271.7

250.0 4.8000 N/A 150 4.0 5.5 R

c

1¼

556

3

/

8”

BSP

TBA TBA

CPx30 19418832.61 30.0 R

c

½0.5760 N/A 0.373 N/A 168¼”

BSP

Rc½ ¼”

BSP

206

CPx45 48.9 45.0 0.8640

m³/h

8294

20736

4147
6221

10368
12096
13824
17280

2074
3110

322 N/A 0.550 N/A

Table 3. Electrical Data

Table 4.1
Burner Pressures - Natural Gas - Group H - G20 - Net CV (H

i

) = 34.02MJ/m³

Riello Burners
Air Gas Start Gas Main Burner Nom. Nett
Model Type Head Gate Pressure Pressure Input Gas Rate CO

2

Flue T.
No No mbar mbar kW m³/h % °C
CPxG 30 GS 5 0 N/A N/A 4.5 32.3 3.42 9.1 145
CPxG 45 GS 10 FF N/A N/A 4.0 49.0 5.18 8.8 160
CPxG 60 GS 10 1 N/A N/A 3.8 64.6 6.84 8.9 143
CPxG 90 GS 10 FF N/A N/A 5.3 98.3 10.40 9.0 170
CPxG 120 GS 20 2 N/A 2.7 4.5 127.4 13.48 8.9 156
CPxG 150 GS 20 FF N/A 3.2 5.7 162.9 17.24 9.2 163
CPxG 175 GS 20 FF N/A 2.9 5.8 190.1 20.11 8.8 157
CPxG 200 GAS 3 4 4 2.9 7.1 215.9 22.84 9.0 148
CPxG 250 GAS 3 FF 7 3.7 8.5 269.9 28.56 9.3 153
CPxG 300 GAS 3 FF 7 4.5 10.2 316.2 31.79 9.5 175

Notes: CO2 values and Nett flue gas temperatures are given for guidance and measured values will depend on site conditions.
FF = Fully Forward

Minimum

Inlet pressure

17.5mbar

Standard Motor Uprated Motor Fitted to EA models as standard
Nominal Plate Start Run Fuse Nominal Start Run Fuse
Model ph Motor Amps Amps Amps Rating Motor Amps Amps Amps
R.P.M. (A) (A) (A) (A) R.P.M. (A) (A) (A)
CPx30 1 1370 3.3 6.5 4.2 5 N/A N/A N/A N/A
CPx45 1 1250 5.0 9.1 5.0 7 N/A N/A N/A N/A
CPx60 1 930 3.1 8.1 4.7 7 N/A N/A N/A N/A
CPx90G 1 900 9.8 18.0 7.2 10 N/A N/A N/A N/A
CPx90O 1 900 9.8 18.0 6.5 10 N/A N/A N/A N/A
CPx120 3 900 5.3 13.1 4.8 7 N/A N/A N/A N/A
CPx150 3 1500 4.91 32.5 5.1 7 1500 25.0 5.75 10
CPx175 3 1500 6.47 20.8 6.9 10 1500 35.0 11.0 15
CPx200 3 1500 8.14 38.0 6.5 10 1500 35.0 8.83 15
CPx250 3 1500 8.14 58.0 9.0 15 1500 35.0 11.65 15
CPx300 3 1500 10.9 80.0 9.7 15 1500 32.0 14.4 15

Page 22 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

Riello Burners
Air Gas Start Gas Main Burner Nom. Nett
Model Type Head Gate Pressure Pressure Input Gas Rate CO

2

Flue T.
No No mbar mbar kW m³/h % °C
CPxG 30 GS 5 1 N/A N/A 2.6 32.7 1.34 9.0 153
CPxG 45 GS 10 FF N/A N/A 6.4 48.5 1.98 10.6 150
CPxG 60 GS 10 1 N/A N/A 4.1 64.5 2.64 10.4 145
CPxG 90 GS 10 FF N/A N/A 8.3 98.0 4.01 10.7 173
CPxG 120 GS 20 2 N/A 2.5 5.9 129.7 5.31 10.6 158
CPxG 150 GS 20 FF N/A 3.7 8.5 162.4 6.64 10.7 161
CPxG 175 GS 20 FF N/A 3.0 8.3 188.8 7.72 10.6 153
CPxG 200 GAS 3 4 4 2.8 10.3 216.1 8.84 10.5 155
CPxG 250 GAS 3 FF 7 4.0 9.8 269.0 11.00 11.4 157
CPxG 300 GAS 3 FF 7 5.0 11.9 314.0 12.84 11.5 171

Table 4.2
Burner Pressures - Propane Gas - G31 - Net CV (Hi) = 88.0MJ/m³

Notes: CO2 values and Nett flue gas temperatures are given for guidance and measured values will depend on site conditions.
FF = Fully Forward

Inlet Pressure

37mbar

Table 5 Pump Pressures - 35sec Oil - Net CV (Hi) = 42.69MJ/kg

Riello Burners
Nozzle Pump Oil Rate Nom. Nett
Model Type Head Make Size Angle Type Pressure Input CO

2

Flue T.
Setting ° bar p.s.i kW kg/h l/h % °C
CPxO 30 G5 2 Danf

oss 0.60 80 S 13.7 200 31.9 2.69 3.16 12.5 146
CPxO 45 G10 1 Danfoss 1.00 60 S 13.1 190 48.7 4.11 4.83 12.5 188
CPxO 60 G10 2 Danfoss 1.25 60 S 13.4 195 64.3 5.42 6.38 12.8 169
CPxO 90 G10 4 Danfoss 2.00 60 S 13.1 190 97.7 8.24 9.70 13.0 202
CPxO 120 G20S 2 Danfoss 2.50 60 S 15.1 220 130.5 11.00 12.95 13.0 205
CPxO 150 G20S 3 Danfoss 3.00 60 S 14.4 210 160.3 13.52 15.90 12.5 188
CPxO 175 G20S 4 Danfoss 3.75 60 B 14.4 210 190.4 16.05 18.89 12.5 198
CPxO 200 G20S 6 Danfoss 4.50 60 B 13.7 200 213.4 17.99 21.17 13.5 166
CPxO 250 Press GBV 3 Danfoss 5.00 45 B 15.8 230 269.4 22.72 26.73 12.8 181
CPxO 300 Press GBV 7 Danfoss 6.00 45 B 15.1 220 316.1 26.65 31.36 13.0 210

Note: CO2 values and Nett flue gas temperatures are given for guidance and measured values will depend on site conditions.

Table 6

Heat Exchanger Baffles

Model CPx30 CPx45 CPx60 CPx90 CPx120 CPx150
Natural Gas None Top Tubes Top Tubes All Tubes Top Tubes All Tubes
Propane None Top Tubes Top Tubes All Tubes Top Tubes All Tubes
Oil - 35 sec. None None None Top Tubes None Top Tubes

CPx175

Top Tubes
Top Tubes

None

CPx200

All Tubes
All Tubes

Top Tubes

CPx250

All Tubes
All Tubes

Top Tubes

CPx300

All Tubes
All Tubes

Top Tubes

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

Oil - 28 sec. None None None Top Tubes None All Tubes None Top Tubes Top Tubes Top Tubes

3.2 Short List of Parts

Refer also to the burner supplement supplied with the heater

ITEM Used on Part Number
Gas Valve Block 30 & 45 141378701
Gas Valve Block 60 & 90 141378702
Gas Valve Block 120 141378703
Gas Valve Block 150, 175 & 200 141378705
Gas Valve Block 250 & 300 141378706
Thermostat - Fan / Limit All 143000306
Contactor 300 143000600
Contactor 120-250 143000601
Overload 300 143000800
Overload 200 143000801
Overload 120/150/175/200 143000802
Soft Start 300LHP 143000620
Heat Exchanger Cleanout Door Gasket. All 170246006
Burner Gasket 30 141937080
Burner Gasket 45 - 90 141930806
Burner Gasket 120 - 175 142931252
Burner Gasket 200 - 300 142931240

4.1 Servicing

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 compo­nents.

4.1.1 General

Full maintenance should be undertaken not less than
once per year. After any servicing work has been com­plete 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 instruc­tions 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 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.

3. Replace panels accordingly.

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 23

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

4.1.6.3.1 CPx 30 - CPx 120

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 neces­sary to remove one or more of the fans for clean­ing 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

Page 24 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

4.1.6.6.4 Fan / Limit Thermostat Hon­eywell 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 over­heat situation.

1. Squeeze the sides of the 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 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.

Fig 4 Thermostat Fan / Limit - Honeywell L4064B

CAUTION

DO NOT ROT ATE - HOLD

DIAL WHEN SETTING POINTERS

5

0

1

0

0

1

5

0

2

0

0

2

5

0

F

A

N

L

I

M

I

T

O

F

F

O

N

O

F

F

Limit Set point
Adjustment

Fan Circuit

OUT

Limit Circuit

OUT

Fan ON

Override

Set Point Dial

Brass Link Location

Mechanical Limiter

Release Point

Mechanical limiter

Fan OFF Set point
Adjustment

NOTE: Temperature points on the dial are in Fahrenheit

Limit Circuit

IN

Fan Circuit

IN

Fan ON Set point
Adjustment

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 25

Refer also to the burner supplement supplied with the heater

Fault Cause Action

Main burner will not light Electrical 1. Check electrical supply is ON.

2. Check controls are ON or calling for heat.

3. Faulty ignition probe/lead/setting.

4. Faulty burner control unit.

5. Limit thermostat open circuit/faulty, interlock relay not
set/faulty
Gas/Oil 1. Check fuel supply is present.

Main burner lights, but goes out before Electrical 1. Unit goes out on high limit ­main fan comes on or whilst controls still a. Check fan thermostat setting - See Section
calling for heat. 4.1.6.6.4. Page25
b. Faulty fan thermostat - change
c. Check limit thermostat setting - See Section 4.1.6.6.4.
Page25
d. Faulty limit thermostat - change.
e. Faulty fan assembly - change.
f. Fan motor out on thermal overload. - Check running
amps.
See Table 3.- check duct resistance See Table 2.
Page 21
g. Check that airflow through the heater is not restricted.
Gas/Oil 1. Check continuity of fuel supply.

Main fan runs continuously Electrical 1. Summer/Winter switch set to Summer - set to Winter.

2. White button on fan/limit thermostat pushed in - pull out.

3. Fan thermostat set too low - check setting See 4.1.6.6.4.
Page25

4. Faulty fan thermostat - change

Main fan fails to run Electrical 1. Fan motor or capacitor failed - replace.

Page 26 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

4.2 Fault Finding

CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014 Page 27

Notes

HEATING DIVISION

Hort Bridge

Ilminster, Somerset TA19 9PS

Tel: [phone]

Fax: [phone]

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continued product

improvement, we reserve the right to alter specification without prior notice.

Page 28 CPx Gas or Oil Cabinet Heater Range Issue 2.1 June 2014

Appendix A

Calculation Of Flue System Equivalent Resistance

The pressure resistance of the flue system (Pr) = 1.5 * [(PFF*H/D+SRF)Qm/Wm2] (pa)
Where H = Effective flue height in m
D = Internal Diameter of flue in m

PRF (Pipe Friction Factor) = 0.118*(0.21147/D0.4)
Where D = Internal Diameter of flue in m

SRF (Sum of individual resistance factors)
Typical resistance factors for individual components are as follows
Segmented 90° bend 0.5
45° Elbow 0.4
Cowl 1.0

Qm (Mean Density of the column of exhaust gas in kg/m3) = 97000/(300*Tm)
Where the mean temperature of the column of exhaust gas (Tm) = 288+((Te-TL)/0.2)*(0.18)
Where Te is the exhaust gas temperature in °C
TL is the external air temperature in °C

Wm (Mean exhaust gas velocity in m/s = M/(A*Qm)
Where A is the cross sectional area of the flue in m2
M is the exhaust gas mass flow in kg/s which is as follows for the various units
CPx 30 0.018 CPx 150 0.125
CPx 45 0.027 CPx 175 0.14
CPx 60 0.035 CPx 200 0.145
CPx 90 0.050 CPx 250 0.16
CPx 120 0.080 CPx 300 0.2