Powrmatic CPx Series, CPx 30, CPx 120, CPx 150, CPx 175 User, Installation & Servicing Manual

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www.powrmatic.co.uk

CPx

Doc Ref: M201 Issue 2.9 Nov 2018

User, Installation & Servicing Manual

Issue 2.9 November 2018

ErP COMPLIANT

SEPTEMBER 2018

Page 2

Certificate Of Guarantee

Certificate of Guarantee

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.

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. As much detail as possible on the fault.

3. 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 qualified installer, and in accordance with the manufacturer’s 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 and qualified servicing company.

4. The heater has been used in accordance with the manufacturer’s instructions.

5. The correct specification fuel has been used.

6. No unauthorised repairs of modifications have been made. Powrmatic ‘General Conditions of Sales’ have been observed.

7. 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 cost arising from loss of use of the heater, or any event arising there from.

Exclusions

Consumables such as gaskets, ignition electrodes, flame rectification electrodes, drive belts, fusible links, control batteries, oil nozzles and oil line filter elements are all excluded from guarantee.

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

Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk e-mail: warranty@powrmatic.co.uk

Important: This certificate

must be kept with the appliance

Failure to provide a copy of the commissioning sheet invalidates the heater warranty

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 3

Contents

Users, Installation and Servicing Instructions

CONTENTS

Title Section Contents Page

User Instructions 4

Pre Installation

1.1 Introduction 6 Duties 7 Dimensions 8 Accessories 15 Head Plans 15

1.2 Technical data 16

1.3 General Requirements 23

Installation

2.1 Fitting the unit 27

2.2 Fitting the flue 29

2.3 General Identification of Items 29

2.4 Electrical Cable Installation 30

2.5 Wiring Diagrams 33

2.6 Commissioning and Testing 36

2.7 Servicing 40

Additional Documents

3.1 Fault Finding Flow Chart 49

3.2 List of Parts 50

3.3 Fuel Conversion 59

Appendices

1. Information required for ecodesign (ErP) Directive 2009/125 64

2. Calculation of flue system equivalent resistance 65

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 3 of 68

Page 4

User Instructions

If the heater has not been left operational proceed as follows.

A) Checks before operating the Air Heater

The following preliminary checks should be made before lighting the heater(s)

a) Ensure that the ELECTRICAL supply to the heater is switched OFF. b) Check that any warm air delivery outlets are open. c) Check that the thermostat is set. d) Check that the clock control is set to an ON period. e) Check that any other controls are calling for heat.

B) Operating 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 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

reset button.

2) Oil-fired Heaters

IMPORTANT: 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 reset button.

If the unit will not light after two to three 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 set to it’s lowest setting.

2) For Long Periods:

Complete step 1 above. Wait for 5 minutes and then turn OFF the electrical supply at the isolator.

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.

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

WARNING: 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.

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

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 to 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 5

E) Fan and Limit Control

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

User Instructions

Warning: Flammable Materials

i) Main Air Fan MAN/Auto

When the white button is pushed to MAN 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.

ii) Limit Thermostat

This operates if high temperatures within the heater are detected, the burner is 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.

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.

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.

Warning: Hot Surfaces

Warning: Contains Moving Parts

Read and understand this Service Manual Instructions before operating or servicing this appliance

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 National Gas Emergency number immediately.

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed, adjusted and, if necessary, converted by qualified persons* in accordance with the

current issue 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.

* Gas Safe Registered Engineer

IMPORTANT

All Powrmatic heaters use either gas or oil plus electricity to power them, they may also

contain moving parts such as pulleys and 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.

Danger: Electricity

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

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Page 6

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 and 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.

/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.

* Gas Safe Registered Engineer

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.

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).

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 7

Technical Specification

CPx

Model 30 45 60 90(gas) 90(oil) 120 150 175 200 250 300 360 440 590

Output

Input (nett CV)

Old Powrmatic Reference CP 100 150 200 300 300 400 500 600 700 800 1000 1250 1500 2000

Thermal Efficiencies (Nett CV) % Min 91.5%

Heads

Airflow

Electrics

Fuel

Overall Dimensions

Installation Clearances

Flue Diameter mm ø 125 125 150 150 150 150 175 175 175 200 200 250 300 300

Combustion Air Spigot mm ø 150 150 150 150 150 150 150 150 150 150 150 150 175 175

Maximum Combustion Duct Length * m 34 34 21 21 21 12 8 6 4 3 2 3 2 2

Noise Level (See Note Below) dB(A) 56 61 61 63 63 70 62 73 74 75 77 78 80 82

Nett Weight (See Note Below)

Throw UF / HF m 15 21 19 24 24 24 29 29 29 41 48 48 30 40

Fan Static

Supply

Standard

Fan

Uprated

Fan (L.H.P.)

Connection

Minimum

Inlet

Pressure

Consumption

Standard

Outputs

UF Upright

Freeblowing

UF Upright

Freeblowing

G20 Gas kW 32.6 48.9 65.2 97.8 n/a 130.4 163.0 190.2 217.4 271.7 315.2 399.0 479.6 638.7

35sec Oil kW 31.9 48.7 64.3 n/a 97.7 130.5 160.3 190.3 213.3 269.4 316.1 391.6 470.8 627

Volume m

UF / HF No. 2 2 3 3 3 4 4 4 4 4 4 4 8 8

Size mm 203 254 254 305 305

Standard Pa 188 222 270 250 200 180 185 290 250 140 150 300 300 300

Up-rated Pa 250 250 400 500 450 350 400 500 500 450 500 600 600 600

Standard V/ph/Hz 230/1/50 400/3/50

Optional V/ph/Hz 400/3/50 230/1/50 n/a

Motor kW 0.55 0.55 1.1 1.5 1.4 1.4 3.0 4.0 4.0 4.0 7.5 11.0 11.0 15.0

Run amp 4.3 5.7 5.3 10.0 9.6 6.4 6.7 7.1 8.6 8.4 14.5 21.3 21.3 28.9

Start amp 8.1 17.1 16.1 25.5 28.1 12.4 23.45 23.0 19.7 28.2 50.1 127.2 127.2 182.4

Motor kW 0.75 0.75 2.2 2.2 1.5 3.0 4.0 5.5 5.5 5.5 11.0 15.0 15.0 18.5

Run amp 5.3 5.3 12.6 12.6 9.2 6.3 8.3 11.0 11.0 11.0 21.6 28.9 28.0 35.0

Start amp 15.9 15.9 37.8 37.8 27.6 22.05 29.05 38.5 38.5 38.5 75.6 182.4 182.4 221.2

Oil BSP/Rc ⅜” ⅜” ⅜” n/a ⅜” ⅜” ⅜” ⅜” ⅜” ⅜” ⅜” ⅜” ⅜” ½”

Gas BSP/Rc ½” ½” ¾” ¾” n/a ¾” 1” 1” 1” 1¼” 1¼” 1½” 1½” 1½”

Nat Gas mbar 17.5 n/a 17.5

LPG mbar 37.0 n/a 37.0

Oil l/h 3.16 4.83 6.38 n/a 9.70 12.95 15.90 18.89 21.17 26.73 31.36 38.82 47.45 63.62

Nat Gas m

LPG m

Height mm 2024 2072 2494 2585 2585 2821 2821 3054 3174 3307 3307 3657 4107 4407

Width mm 669 669 744 744 744 904 904 904 904 1104 1104 1260 1330 1330

Depth

(Excludes

burner)

Front mm 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Side mm 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Blank Side mm 150 150 150 150 150 150 150 150 150 150 150 n/a n/a n/a

Rear mm 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Model 30 45 60 90(gas) 90(oil) 120 150 175 200 250 300 360 440 590

* For extended combustion duct lengths please contact Powrmatic

Notes –

• Fuel consumption and output figures based upon nett calorific values as follows

- Class D light distillate fuel oil nett CV 36.28 MJ/l

- Natural gas (G20) nett CV 34.02 MJ/m³

- Propane (G31) nett CV 88.00 MJ/m³

• C Px heaters comply w ith the seasonal e fficienc y and NOx limits requirements of the Ecodesig n regulation (EU) 2015/1188, Direct ive 2009/125/EC – Lot 21 Tier 1

• Air handling data is assessed at room ambient conditions

• Throw figures provide the distance to the point where the terminal velocity degrades to 0.25 m/s

• Overall vertical heater height include heads or extended heads where appropriate

• Standard height heads can be specified where site height is restricted

• Blank and louvred lower side panels are interchangeable

• Dimensions in table above refer to upright heaters only - for horizontal and counterflow heater dimensions refer to dimensions page

• Noise levels are applicable to standard UF models and are measured 5m from appliance and in free field conditions

• Motor kW, run and start amps apply to standard electrical supply as stated. For optional data contact sales office

• Nett weight figures apply to standard upright CPx heaters only

• It is the responsibility of the installing contractor to ensure that ductwork is correctly sized and balanced when installing a ducted unit.

kW 30 45 60 90 90 120 150 175 200 250 290 366 440 586

/s 0.97 0.86 1.01 2.11 1.50 2.30 3.15 3.36 3.84 4.49 5.76 6.49 7.88 10.5

305/358 305/358

/h 3.45 5.17 6.89 10.34 n/a 13.79 17.23 20.11 22.99 28.73 33.33 41.41 50.61 67.86

/h 1.34 1.98 2.64 4.01 n/a 5.31 6.64 7.72 8.84 11.00 12.84 16.00 19.56 26.23

mm 732 732 927 927 927 1200 1200 1399 1399 1599 1599 1915 2165 2715

kg 168 173 231 241 241 341 386 530 530 556 556 1012 1380 1720

358 406 457 457 457 457 457

1000 1000

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

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Page 8

Dimensions

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

ØD

Notes -

• Flue tee provided as standard.

Model 30 45 60 90 120 150 175 200 250 300

A All mm 732 732 927 927 1200 1200 1399 1399 1599 1599

B All mm 669 669 744 744 904 904 904 904 1104 1104

C All mm 1767 1767 1895 1895 2149 2149 2265 2265 2265 2265

D All mm ø 125 125 150 150 150 175 175 175 200 200

E All mm 150 150 150 150 150 200 200 200 240 240

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

Gas mm 276 276 252 280 280 280 300 300 300 508

J1 All mm n/a n/a 581 672 672 672 788 875 1007 1007

K All mm 180 234 234 287 287 287 333 381 431 431

K1 All mm n/a n/a n/a n/a 333 333 n/a n/a n/a n/a

M mm 569 569 644 644 804 804 804 804 1004 1004

Oil mm 196 202 202 228 228 228 228 247 247 508

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

Duct

Spigot

mm 632 632 824 824 1100 1100 1299 1299 1499 1499

Head Plan 1 1 2 2 3a 3a 3b 3b 3b 3b

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 9

Dimensions

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

ØD

Notes -

• Flue tee provided as standard.

• Screened air intake (SAI) fitted as standard on HF models. Duct spigot option available.

• Direction of airflow to be specified at time of order. Left to Right (L-R when looking at the burner) airflow shown above.

Model 30 45 60 90 120 150 175 200 250 300

A All mm 732 732 927 927 1200 1200 1399 1399 1599 1599

B All mm 669 669 744 744 904 904 904 904 1104 1104

C All mm 1767 1767 1895 1895 2151 2151 2265 2265 2265 2265

D All mm ø 125 125 150 150 150 175 175 175 200 200

E All mm 150 150 150 150 150 200 200 200 240 240

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

Gas mm 276 276 252 280 280 280 300 300 300 508

J All mm 227 227 260 260

K All mm 180 234 234 287 287 287 333 381 431 431

K1 All mm n/a n/a n/a n/a 333 333 n/a n/a n/a n/a

M mm 569 569 644 644 804 804 804 804 1004 1004

N All mm 125 125 125 125 150 150 150 150 150 150

Oil mm 196 202 202 228 228 228 228 247 247 508

260 260 297 297 367 367

Duct

Spigot

mm 632 632 824 824 1100 1100 1299 1299 1499 1499

Head Plan 1 1 2 2 3a 3a 3b 3b 3b 3b

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 9 of 68

Page 10

Dimensions

CPx-EA External Cabinet Heaters (30-300)

Upright models

ØD

1 mtr

Horizontal models

Optional Fresh Air Intake Grille

1 mtr

Optional Fresh Air Intake Grille

Notes -

• Direction of airflow to be specified at time of order. Left to Right (L-R when looking at the burner) airflow shown above.

• Inlet and Outlet duct spigots have the same dimensions (Horizontal units only)

• Primary flue length, cowl and flashing provided as standard.

A All mm 1184 1184 1379 1379 1692 1692 1891 1891 2280 2280

B All mm 669 669 744 744 904 904 904 904 1104 1104

C All mm 1767 1767 1895 1895 2149 2149 2265 2265 2265 2265

D All mm ø 125 125 150 150 150 175 175 175 200 200

E All mm 150 150 150 150 150 200 200 200 240 240

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

M mm 569 569 644 644 804 804 804 804 1004 1004

N All mm 125 125 125

Model 30 45 60 90 120 150 175 200 250 300

Duct

Spigot

mm 632 632 824 824 1100 1100 1299 1299 1499 1499

125 150 150 150 150 150 150

page no. 10 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 11

Upright models

Dimensions

CPx UD/UF Upright Free Blowing Upright Ducted (360-590)

Notes -

• The Heat Exchanger and Fan Section can be split on the ‘Section Split Line’.

• Flue tee provided as standard.

ØD

Section

Split Line

200

Model 360 440 590

A All mm 1915 2165 2715

B All mm 1260 1330 1330

C All mm 2615 3065 3365

D All mm ø 250 300 300

E All mm 865 965 1265

F All mm 1550 1900 1900

H All mm 2152 2537 2837

J All mm 558 558 558

J1 All mm 1007 1007 1007

K All mm 431 431 431

M mm 1160 1230 1230

Gas mm 508 580 840

Oil mm 508 468 680

Duct Spigot

mm 1815 2065 2615

Head Plan 3b 4 4

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 11 of 68

Page 12

Dimensions

CPx HD/HF Upright Free Blowing Upright Ducted (360-590)

Horizontal models

ØD

Section Split Line

M B

200

Notes -

Model 360 440 590

A All mm 1915 2165 2715

B All mm 1260 1330 1330

C All mm 2800 3250 3600

D All mm ø 250 300 300

E All mm 1250 1350 1700

F All mm 1550 1900 1900

H All mm 830 865 865

M mm 1160 1230 1230

Gas mm 580 580 840

Oil mm 468 468 680

Duct Spigot

mm 1815 2065 2615

Head Plan 3b 4 4

• The Heat Exchanger and Fan Section can be split on the ‘Section Split Line’. Flue tee provided as standard.

• Direction of airflow to be specified at time of order.

Right to Left (R-L when looking at the burner) airflow shown above.

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 13

Upright models

Dimensions

CPx-EA External Cabinet Heaters (360-590)

1 mtr

ØD

Section Split Line

200

Notes -

• The Heat Exchanger and Fan Section can be split on the ‘Section Split Line’.

• Return air via inlet duct spigot is standard. Optional fresh air grille is available.

• Primary flue and cowl provided as standard.

Model 360 440 590

A All mm 1915 2165 2715

B All mm 1260 1330 1330

C All mm 2615 3065 3365

D All mm ø 250 300 300

E All mm 865 965 1265

F All mm 1550 1900 1900

G All mm 650 650 950

H All mm 2565 2815 3665

M mm 1160 1230 1230

P All mm 760 860 1160

Duct Spigot

mm 1815 2065 2615

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 13 of 68

Page 14

Dimensions

CPx-EA External Cabinet Heaters (360-590)

Horizontal models

1 mtr

ØD

Section Split Line

200

Notes -

• The Heat Exchanger and Fan Section can be split on the ‘Section Split Line’. Primary flue and cowl provided as standard.

• Direction of airflow to be specified at time of order. Right to Left (R-L when looking at the burner) airflow shown above.

Model 360 440 590

A All mm 1915 2165 2715

B All mm 1260 1330 1330

C All mm 2800 3250 3600

D All mm ø 250 300 300

E All mm 1250 1350 1700

F All mm 1550 1900 1900

G All mm 650 650 950

H All mm 2565 2815 3665

M mm 1160 1230 1230

Duct Spigot

mm 1815 2065 2615

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CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 15

Accessories

Side/rear Inlet Spigots Filters Dampers

SIDE REAR

Model 30 45 60 90 120 150 175 200 250 300 360 440 590

A All mm 732 732 927 927 1200 1200 1399 1399 1599 1599 1915 2165 2715

B All mm 669 669 744 744 904 904 904 904 1105 1105 n/a n/a n/a

C All mm 630 630 825 825 1098 1098 1300 1300 1500 1500 1815 2065 2615

D All mm 567 567 642 642 802 802 802 802 1003 1003 n/a n/a n/a

E All mm 685 685 738 738 838 838 838 838 838 838 865 965 1265

F All mm 627 627 677 677 775 775 775 775 775 775 n/a n/a n/a

G All mm 585 585 640 640 738 738 738 738 738 738 765 865 1165

H All mm 527 527 577 577 675 675 675 675 675 675 n/a n/a n/a

J All mm 136 136 136 136 136 136 136 136 136 136 250 250 250

Notes -

• All dimensions are outside dimensions

• Vertical units shown - for horizontal units please contact our sales office

• Standard filter specification is 10ppi

• Higher specification filters available on request - contact our sales team for more information

• Standard dampers are manual operation - motorised options available

Head Plan 1

(30 & 45)

Head Plan 3b

(75, 200, 250, 300 & 360)

Head Plan 2

(60 & 90)

Head Plans

Head Plan 3a

(120 & 150)

Head Plan 4 (440 & 590)

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 15 of 68

Page 16

1.2 Technical Data

Riello Burner Settings - Natural Gas - Group H - G20 Net CV (Hi = 34.02MJ/m³)

Nominal Inlet Pressure = 20mbar Minimum Inlet Pressure = 17.5mbar

High Fire Low Fire

MODEL Burner Type Gas Control

CPx30 BS1D MB405/2 3.4 3.45 1.5 2.11

CPx45 BS1D MB405/2 6.4 5.00 2.5 2.85

CPx60 BS2D MB407/2 5.8 6.89 2.5 4. 32

CPx90 BS3D MB407/2 4.2 10.34 1.9 6.82

CP x120 BS3D M B 407/ 2 6.0 13. 47 2.6 8 . 61

CP x150 BS3D MB 410/2 9.1 17. 23 3.3 10.02

CP x175 BS4D MB410/2 8.3 20.10 3.5 13.90

CPx200 RS5D MB410/2 6.9 22.99 4.1 16.15

CPx250 RS5D MB 412/2 9.3 28.46 5.8 14.38

CPx300 RS34 MZ MBDLE415 tbc tbc tbc tbc

MODEL

Head

Setting

no.

Combustion Air

Pressure

High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire

Burner Pressure Gas Rate Burner Pressure Gas Rate

mbar m/h mbar m/h

Air

Switch*

Flue

Pressure

Switch*

Nominal CO2

(±0.5)

Nox Nett Flue Temp

No. No. No. mbar Pa % % ppm ppm °C °C

CPx30 1 2.8 1.0 2.1 40 9.2 8.75 24.7 26.8 132 74

CPx45 4 6.0 1.0 2.7 20 8.7 9 .1 23.5 29.4 171 75

CPx60 4 2.0 1.0 2.0 120 8.75 9.0 27. 9 28.8 145 78

CPx90 1 1.3 0.25 3.0 110 8.8 9.3 27. 5 33.2 154 92

CPx120 5 2 .1 1.0 5.0 280 9.2 8.8 34.5 31.9 174 102

CPx150 7 5.0 1.1 5.0 220 9.3 9.2 29.5 35.5 165 82

CP x175 7 5.3 1.8 3.6 270 9.3 8.6 28.4 32.3 158 89

CPx200 0 (39) (22) 4.0 300 9.0 8.8 41.4 40.0 141

CPx250 10 (63) (30) 4.0 300 8.8 8.4 44.0 44.3 142 79

CPx300 tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc

Notes: CO2 values and Nett flue gas temperatures are given for guidance and measured values will depend on site conditions. * Air Pressure Switch settings are given for guidance and measured values will depend on site conditions.

page no. 16 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 17

Riello Burner Settings - Propane G31 Net CV (Hi = 88.00MJ/m³)

Nominal Inlet Pressure = 37mbar Minimum Inlet Pressure = 37mbar

High Fire Low Fire

1.2 Technical Data

MODEL Burner Type Gas Control

CPx30 BS1D MB405/2 5.0 1.33 2.7 0.91

CPx45 BS1D MB405/2 10.2 1.93 3.9 1.1

CPx60 BS2D M B4 07/ 2 8.2 2.67 3.5 1.67

CPx90 BS3D MB 407/2 5.5 4.0 2.6 2.64

CPx120 BS3D MB 4 07/2 7.6 5.21 3.5 3.33

CPx150 BS3D M B 410/2 10.6 6.66 4.4 3.87

CP x175 BS4D MB 410/2 tbc tbc tbc tbc

CPx200 RS5D M B410/ 2 6.9 8.8 3.9 6.24

CPx250 RS5D MB 412/2 10.0 11.0 4.7 7.49

CPx300 RS34MZ MBDLE415 tbc tbc tbc tbc

MODEL

Head

Setting

no.

Combustion Air

Pressure

High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire

Burner Pressure Gas Rate Burner Pressure Gas Rate

mbar m/h mbar m/h

Air

Switch*

Flue

Pressure

Switch*

Nominal CO2

(±0.5)

Nox Nett Flue Temp

No. No. No. mbar Pa % % ppm ppm °C °C

CPx30 3 1.1 1.0 1.5 60 9.6 9.0 40.5 40.0 118 73

CPx45 4 6.0 1.4 2.7 100 10.9 10.3 35.4 40.4 166 82

CPx60 3 2.3 1.0 2 150 9.5 9.8 29.2 47.7 160 81

CPx90 2 1.3 0.5 3 110 10.5 9.95 46.2 48.8 148 94

CPx120 4 2 .1 0.9 5 280 10.73 9.9 50.3 49.5 177 122

CPx150 6 3.6 1.0 4 220 10.9 10.26 46.8 48.0 137 73

CP x175 tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc

CPx200 2 39 29 4 300 10.33 9.9 64 53.0 140

CPx250 7 50 21 3 300 11.1 11.1 74 75.0 125 72

CPx300 tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc tbc

105

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 17 of 68

Page 18

1.2 Technical Data

Riello Burner Settings - 35sec Oil - Diesel - Net CV (Hi = 42.69MJ/kg)

High Fire Low Fire

MODEL Burner Type Nozzle

CPx30 RG1RKD 0.65 x 80S 13.44 195 2.70 8.96 130 1.89

CPx45 RG2D 1.00 x 60S 14.48 210 4.15 8.96 130 3.27

CPx60 RG2D 1.25 x 60S 14 .13 205 5.36 8.96 130 4.07

CPx90 RG3D 2.00 x 60S 13.79 200 8.28 8.27 120 6 .16

CPx120 RG3D 2.75 x 60S 12.07 175 10.91 8.96 130 8.50

CPx150 RG3D 3.00 x 60S 15.17 220 13.45 8.96 130 9.82

CP x175 RG4D 3.75 x 60B 15 .17 220 16.45 8.27 120 11.59

CPx200 RG5D 2.5 + 2.0 x 60S 13 .10 190 17. 9 6 13.10 190 10.01

CPx250 RG5D 3.0 + 2.5 x 60S 13.1 0 190 23.69 13 .10 190 13.07

CPx300 RL34 MZ TC 4.0 + 2.75 x 60S 11.03 160 25.30 11.03 160 15.00

MODEL

Head

Setting

no.

Combustion Air Nominal CO (±0.5) Nox

High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire

Burner Pressure Fuel Input Burner Pressure Fuel Input

bar psi kg/h bar psi kg/h

Nett Flue Temp

Smoke

No. No. No. % % ppm ppm No. °C °C

CPx30 1.3 1.5 0.25 11. 8 12.5 67. 5 65.5 0 -1 133 96

CPx45 0 1.1 0.25 12.5 12.6 70.3 65.3 0-1 209 138

CPx60 2 1.9 0.45 12.7 12.6 74.5 65.0 0 -1 158 110

CPx90 0.5 0.8 0.2 12.5 12.5 80.3 68.2 0 -1 214 138

CPx120 3 1.6 0.4 12.7 12.5 57.6 4 9 .1 0-1 213 169

CPx150 5 2.9 0.8 12.7 12. 2 65.3 49.9 0-1 182 139

CP x175 3 4.2 0.5 13.0 11. 8 68.5 51.8 0-1 213 146

CPx200 6 4.0 0.4 12.4 12.1 91.2 65.8 0 -1 157 79

CPx250 8 6.0 0.6 12.7 12.4 83.6 62.4 0 -1 219 117

CPx300 6 (70) (30) 12.6 12.1

Notes: CO values and Nett ﬂue gas temperatures are given for guidance and measured values will depend on site conditions. * Air Pressure Switch settings are given for guidance and measured values will depend on site conditions.

tbc tbc 0 -1 tbc tba

page no. 18 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 19

1.2 Technical Data

Riello Burner Settings - 28sec Oil - Kerosene - Net CV (Hi = 47.00MJ/kg)

High Fire Low Fire

MODEL Burner Type Nozzle

CPx30 RG1RKD 0.75 x 60S 10.0 140 2.70 7. 0 100 1.89

CPx45 RG2D 1.25 x 60S 10.0 140 4.15 7.0 100 3.27

CPx60 RG2D 1.50 x 60S 10.0 140 5.36 7.0 100 4.07

CPx90 RG3D 2.50 x 60S 10.0 140 8.28 7.0 100 6 .16

CPx120 RG3D 3.00 x 60S 10.0 140 10.91 7.0 100 8.50

CPx150 RG3D 3.75 x 60B 10.0 140 13.45 7. 0 100 9.82

CP x175 RG4D 4.50 x 60B 10.0 140 16.45 7.0 100 11.60

CPx200 RG5D 2.5 + 2.0 x 60S 10.0 140 17.9 6 10.0 140 10.00

CPx250 RG5D 3.5 + 3.0 x 60S 10.0 140 23.69 10.0 140 13.10

CPx300 RL34 MZ TC

Head

MODEL

Setting

no.

High Fire Low Fire High Fire Low Fire High Fire Low Fire High Fire Low Fire

Combustion Air Nominal CO (±0.5) Nox

4.5x60B + 3x60S

Burner Pressure Fuel Input Burner Pressure Fuel Input

bar psi kg/h bar psi kg/h

tbc tbc tbc tbc tbc tbc

Nett Flue Temp

Smoke

No. No. No. % % ppm ppm No. °C °C

CPx30 1.3 1.5 0.25 11. 8 12.5 67. 5 65.5 0 -1 133 96

CPx45 0 1.1 0.25 12.5 12.6 70.3 65.3 0-1 209 138

CPx60 2 1.9 0.45 12.7 12.6 74.5 65.0 0 -1 158 110

CPx90 0.5 0.8 0.2 12.5 12.5 80.3 68.2 0 -1 214 138

CPx120 3 1.6 0.4 12.7 12.6 57.6 4 9 .1 0-1 213 169

CPx150 5 2.9 0.8 12.7 12. 2 65.3 49.9 0-1 182 139

CP x175 3 4.2 0.5 13.0 11. 8 68.5 51.8 0-1 213 146

CPx200 6 4.0 0.4 12.4 12.1 91.2 65.8 0 -1 157 79

CPx250 8 6.0 0.6 12.7 12.4 83.3 62.4 0-1 219 117

CPx300 tbc tbc tbc tbc tbc

tbc tbc tbc tbc tbc

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 19 of 68

Page 20

1.2 Technical Data

Electrical Loadings

Standard Motor Uprated Motor (fitted to EA models as standard)

MODEL

CPx30 0.55 1 1500 8.1 4.3 6 0.75 1 1500 15.9 5.3 6

CPx45 0.55 1 1500 17.1 5.7 10 0.75 1 1500 15.9 5.3 6

CPx60 1.1 1 1000 16 .1 5.3 6 2.2 1 1500 3 7. 8 12.6 16

CPx90G 1.5 1 1500 25.5 10.0 16 2.2 1 1500 37. 8 12.6 16

CPx90O 1.4 1 1000 2 8 .1 9.6 16 1.5 1 1500 27.6 9.2 16

CPx120 1.7 3 1000 12.4 6.4 10 3.0 3 1500 22.05 6.3 10

CPx150 3.0 3 1500 23.5 6.7 10 4.0 3 1500 29.05 8.3 10

CP x175 4.0 3 1500 23.0 7.1 10 5.5 3 1500

CPx200 4.0 3 1500 19.7 8.6 10 5.5 3 1500 38.5 11.0 16

CPx250 4.0 3 1500 28.2 8.4 10 5.5 3 1500 38.5 11.0 16

CPx300 7.5 3 1500 5 0.1 14.5 16 11.0 3 150 0 75.6 21.6 32

Motor Pha

kW r.p.m A A A kW r.p.m A A A

Nominal

Motor

Start

Amps

Run

Amps

Fuse

Rating

Motor Pha

Nominal

Motor

Start

Amps

38.5 11.0 16

Run

Amps

Heater Specifications

MODEL

Air Volume

(UF/HF)

m³/s m ³/h qty mm m Pa Pa dB(A) kg kg kg

Heads

Throw

(UF/

HF)

Max Duct Resistance

Std Motor Uprated

Noise

Level (std

UF/HF)

Weight

CPx

Weight

CPX/

NCA

Fuse

Rating

Weight

CPx/

CPx30 0.97 3492 2 203 15 188 250 67.7 168 tbc tbc

CPx45 0.86 3096 2 254 21 222 250 35.8 173 tbc tbc

CPx60 1.01 3636 3 254 19 270 400 63.9 231 tbc tbc

CPx90G 2.11 7596 3 305 24 250 500 70.5 241 tbc tbc

CPx90O 1.50 5400 3 305 24 200 450 69.2 241 tbc tbc

CPx120 2.30 8280 4

CPx150 3.15 113 40 4

CP x175 3.36 12096 4 256 29 290 500 71.0 530 tbc tbc

CPx200

CPx250 4.49 16164 4 457 41 140 450 72.7 556 tbc tbc

CPx300 5.76 20736 4 457 48 150 500 77. 0 556 tbc tbc

3.84 13824 4 406 29 250 500 72.0 530 tbc tbc

305/358

24 180 350 71.5 341 tbc tbc

29 185 400 70.0 386 tbc tbc

Heat Exchanger Baffles

Model 30 45 60 90 120 150 175 200 250 300

Nat Gas G20 None Top tubes Top tubes All tubes Top tubes All tubes Top t u b es All tubes All tubes All tubes

Propane G31 None Top tubes Top tubes All tubes Top tube s All tubes Top tubes All tubes All tubes All tubes

Oil - 35 sec None None None Top tubes None To p t ubes None Top tubes None Top t ubes

Oil - 28 sec None None None Top tubes None All tubes None Top t ubes None Top tubes

page no. 20 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 21

Drive Data - Standard Motor

1.2 Technical Data

MODEL

CPx30

CPx45

CPx60

CPx90G

CPx90O

CPx120

CPx150

CP x175

CPx200

CPx250

CPx300

Fan Pulley (e)

Motor (a) Motor Pulley (b)

kW Pha RPM Pt no. Size Pt no. Size Pt no.

0.55 1 1500 n/a n/a n/a n/a n/a 1 270 x 270 1402CFAN150/T/15

0.55 1 1500 n/a n/a n/a n/a n/a 1 270 x 270 1402CFAN14 0/T/15

1.1 1 1000 n/a n/a n/a n/a n/a 1 321 x 321 1402CFAN210/T15

1.5 1 150 0 140001908 170 x1 SPA 142001689 1610 -24 142003360 2 381 x 381 1402CFAN510/T

1.4 1 1000 n/a n/a n/a n/a n/a 1 381 x 381 1402CFAN560/T/15

1.7 3 1000 n/a n/a n/a n/a n/a 1 381 x 381 1402CFAN580/T/15/3P

3.0 3 1500 140002055 95x1 SPA 142000602 1210 -28 142003856 2 457 x 486 1402CFAN820/T

4.0 3 150 0 140002108 95x1 SPA 142000602 1210 -28 142003856 2 457 x 486 1402CFAN820/T

4.0 3 150 0 140002108 160x1 SPA 142001619 1610 -28 142161028 3 381 x 381 x2 1402CFAN510/T/2DECK

7.5 3 1500 140002251 160x1 SPA 142001619 1610 -3 8 142003655 3 381 x 381 x2 1402CFAN510/T/2DECK

Fan Pulley

TaperLock (f)

Belt(s) (g) Fuse

Motor Pulley TaperLock (c)

Centrifugal Fan (d)

Size Pt no.

type

Contactor/Relay/

Soft Start

Overload

Size Pt no. Size Pt no. Size Pt no. T (A) Pt no. Type Pt no. Type Pt no.

n/a n/a n/a n/a n/a n/a 6A 140700046 JOX 143000816 n/a n/a

n/a n/a n/a n/a n/a n/a 10A 140700040 JOX 143000816 n/a n/a

280X1 SPA 142002604 2012-25 142201225 A1690/65 142116903 12 A 140700042 JOX 143000816 n/a n/a

n/a n/a n/a n/a n/a n/a 12 A 140700042 JOX 143000816 n/a n/a

n/a n/a n/a n/a n/a n/a n/a n/a 5.5kW AC3 143000601 5-8A 143000802

200x1 SPA 142001825 2012-25 142201225 XPA170 0 142119742 n/a n/a 5.5kW AC3 143000601 5-8A 143000802

170x1 SPA 142001689 1610-25 142003370 XPA1632 142119730 n/a n/a 5.5kW AC3 143000601 7-11A 143000801

160x1 SPA 142001619 1610-25 142003370 XPA163 2 142119730 n/a n/a 5.5kW AC3 143000601 7-11A 143000801

280x1 SPA 142002604 2012-25 142201225

250x1 SPA 142002494 2012-25 142201225 XPA1632 142119730 n/a n/a 11.0 kW MCI 143000621 12-18A 143000800

XPA1700 142119742 n/a n/a 5.5kW AC3 143000601 12-18A 143000801

Fan type 2

Fan type 1

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 21 of 68

Page 22

1.2 Technical Data

Drive Data - LHP (Larger Horsepower) Motor

MODEL

CPx30

CPx45

CPx60

CPx90G

CPx90O

CPx120

CPx150

CP x175

CPx200

CPx250

CPx300

Fan Pulley (e)

Motor (a) Motor Pulley (b)

kW Pha RPM Pt no. Size Pt no. Size Pt no.

0.75 1 150 0 140001520 95x1 SPA 142000602 1210-24 142003350 2 321 x 321 1402CFAN240/T

2.2 1 150 0 140001998 170x1 SPA 142001689 1610-24 142003360 2 381 x 381 1402CFAN510/T

2.2 1 150 0 140001998 180x1 SPA 142001675 1610 -24 142003360 2 381 x 381 1402CFAN510/T

1.5 1 150 0 140001908 170 x1 SPA 142001689 1610 -24 142003360 2 381 x 381 1402CFAN510/T

3.0 3 1500 140002055 95x1 SPA 142000602 1210 -28 142003856 2 457 x 486 1402CFAN820/T

4.0 3 150 0 140002108 100x1 SPA 142000601 1610 -28 142161028 2 457 x 486 1402CFAN820/T

5.5 3 1450 140002206 95x1 SPA 142000602 1210-28 142003856 2 457 x 486 1402CFAN820/T

5.5 3 1450 140002206 100x1 SPA 142000601 1610-28 142003655 2 457 x 486 1402CFAN820/T

5.5 3 1450 140002206 170 x1 SPA 142001689 1610-28 142003655 3 381 x 381 x2 1402CFAN510/T/2DECK

11.0 3 1500 140002610 140x2 SPA 142001013 2012-42 142201242 3 381 x 381 x2 1402CFAN510/T/2DECK

Fan Pulley

TaperLock (f)

Belt(s) (g) Fuse

Motor Pulley TaperLock (c)

Centrifugal Fan (d)

Size Pt no.

type

Contactor/Relay/

Soft Start

Overload

Size Pt no. Size Pt no. Size Pt no. T (A) Pt no. Ty pe Pt no. Type Pt no.

170x1 SPA 142001689 1610-25 142003370 A10 20/44 142111504 6A 140700046 JOX 143000816 n/a n/a

180x1 SPA 142001675 1610 -25 142003370 A1020/44 142111504 6A 140700046 JOX 143000816 n/a n/a

280x1 SPA 1420026 04 2012-25 142201225 A1690/65 142116903 12 A 140700042 5.5kW AC3 143000601 12-18A 143000800

280x1 SPA 1420026 04 2012-25 142201225 A1690/65 142116903 n/a n/a 5.5kW AC3 143000601 12-18A 143000800

280x1 SPA 1420026 04 2012-25 142201225 A1690/65 142116903 12 A 140700042 JOX 143000816 n/a n/a

200x1 SPA 142001825 2012-25 142201225 X PA1700 142119742 n/a n/a 5.5kW AC3 143000601 5-8A 143000802

200x1 SPA 142001825 2012-25 142201225 X PA1700 142119742 n/a n/a 5.5kW AC3 143000601 7-11A 143000801

160x1 SPA 142001619 1610 -25 142003370 XPA1632 142119730 n/a n/a 7.5k W M C I 143000620 9-13A 143000828

280x1 SPA 1420026 04 2012-25 142201225

190x2 SPA 142001823 2012-25 142201225 XPA15 5 0 142119725 n/a n/a 11.0K W MCI 143000621 17-24A 143000807

XPA1700 142119742 n/a n/a 7.5k W M C I 143000620 9-13A 143000828

page no. 22 of 68

Fan type 3

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 23

1.3 General Requirements

1.3.1. 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.

1.3.2 Location

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.

1.3.3 Sizing of the heater

The heater should be correctly sized for the area that it is heating. Full calculations need to be preformed to ensure the correct KW output heater is fitted (CIBSE elemental methodology can be used, or the Powrmatic Technical Department can provide guidelines).

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, 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.

1.3.4. Electrical Supply

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.

All heaters are supplied by either 230V - 1ph, 50Hz or 415V - 3ph, 50Hz (see technical data or data plate on heater for exact). The method of connection to the main electricity supply must:-

- facilitate the complete electrical isolation of the unit(s)

- be in a readily accessible position adjacent to the unit(s)

- serve only the unit(s)

- have a contact separation of at least 3mm in all poles. See the accompanying wiring diagram for the heater electrical connections.

1.3.5 Flue System

Only flue systems supplied through Powrmatic Ltd may be used with CPx units. Several configurations of flue and combustion air ducts are available.

The flue must terminate in a freely exposed position and be sited to prevent the products of combustion entering any opening in a building in such concentration as to be prejudicial to health or a nuisance.

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 23 of 68

Page 24

1.3 General Requirements

1.3.6. Gas Fired Heaters

1.3.6.1. Related Documents

All Gas Fired CPx heaters comply with the following European Directives:

Energy Related Product Directive: 2009/125/EC* Gas Appliance Directive: 2009/142/EC Electromagnetic Compatibility Directive: 2004/108/EC Low Voltage Directive: 2006/95/EC Machinery Directive: 2006/42/EC

Air heater(s) must be installed in accordance with BS6230 and BS5440 plus any relevant requirements of local and national building codes. * where appropriate.

1.3.6.2 Gas Supply

A servicing valve and union to facilitate servicing must be fitted to the gas inlet pipe work of the heater. The gas supply 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.

1.3.7. Gas Fired Heaters

1.3.7.1. Related Documents

All Oil Fired CPx heaters comply with the following European Directives:

Energy Related Product Directive: 2009/125/EC* Electromagnetic Compatibility Directive: 2004/108/EC Low Voltage Directive: 2006/95/EC Machinery Directive: 2006/42/EC

Air heater(s) must be installed in accordance with BS6230 and BS5440 plus any relevant requirements of local and national building codes. * where appropriate

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.

1.3.7.2 Oil Supply

1.3.6.2 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.

1.3.6.3 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.

1.3.6.4. 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.

Construction and installation of service tanks and fittings should be in accordance with: (a) BS 5410 Part 2 Section 6,

(b) BS 799 Part 5 & (c) BS 1563

In addition the service tank installation must comply with local regulations and by-laws and with the requirements of insurance companies

Refer to the detail provided in the burner handbook regarding oil pipe sizing. These must be generally in accordance with BS799 Part 3 and BS5410 Part 2. Particular attention is drawn to the following: a) Pipe jointing compounds must be capable of withstanding the solvent action of the fuel oil under all operating temperatures and pressures. Jointing compounds containing oil shall not be used. Hemp and other fibrous materials shall not be used as packing for screwed joints. b) Soft solder copper tube fittings and galvanised pipes and fittings must not be used. c) Oil lines must be completely air-tight. d) The pump suction must not exceed a maximum of 0.4 bar (30cm Hg). Beyond this limit gas may be released from the oil.

WARNING: The burners are supplied adjusted for a single pipe system. If the burner is to be used on a twin pipe system the Internal bypass plug of the burner oil pump must be

fitted. Refer to the burner instruction booklet.

page no. 24 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 25

1.3 General Requirements

Ideally the return pipe should terminate within the oil tank at the same level as the suction line, both being below the minimum oil level.

1.3.7.3. Fire Valve

It is recommended that the fire valves should be installed as follows:

1. Main storage to service tank supply (if applicable)

2. Main storage to burner supply

3. Service tank to burner supply (if applicable) Fire valves should be installed generally in accordance with the requirements of BS799: Part 5. The fire valve should be situated in an easily accessible position as near the tank as possible and where practicable within the boundary of the tank chamber or catchpit retaining wall.

1.3.8. Combustion & Ventilation Air Supply

Type B flued installations.

Where CPx heaters are installed within the heated space

(ie not in a plant room or an enclosure) and having a

building design air change rate of greater than 0.5/h, additional provision for ventilation is not required. If the building design air change rate is less than 0.5/h, additional provision for natural or mechanical ventilation

is required. These being:

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.

Type B flued installations.

Where CPx heaters are installed in a plant room or

an enclosure (ie not within the heated space) having

combustion air drawn directly from the room and connected to a flue that evacuates the products of combustion directly from the room additional provision for natural or mechanical ventilation is required. These being:

Natural Ventilation:

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.

Typ e B23 Installation (these refer to section 1.4.3 of these 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.

In the heated

CPx

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 64.62 129.2 258.5 129.2 646.2 323 .1

90 98.31 196.6 393.2 196.6 9 83 .1 491.5

120 127.43 254.9 509.7 254.9 1274.3 6 37.1

150 162.90 325.8 651.6 325.8 1629.0 814.5

175 190.07 3 80 .1 760.3 38 0.1 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

Input

space

Low level grille.

Free area cm²

In a plant room, ventilation to

outside

Low level grille.

Free area cm²

High level grille.

Free area cm²

In an enclosure, ventilation to

outside

Low level grille.

Free area cm²

High level grille.

Free area cm²

300 316.25 632.5 1265.0 632.5 3162.5 1581.2

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 25 of 68

Page 26

1.3 General Requirements

1.3.9. Air Distribution System

1.3.9.1. Freeblowing UF/HF/CF/RF

These are equipped with rotatable air delivery heads fixed to the top panel of the unit providing rotational and lateral direction. The quantity of heads depend on the heater size (see Head Plans in section 1.2) and consist of a number of standard and extended heads. Extended heads are placed on the rear of the heater when located adjacent to a wall to allow complete freeblowing access without any restrictions.

NOTE: We do not recommend removing and blanking off any of these heads or removing singular heads and replacing with similar sized spiral ductwork. Ducted units are available for these applications.

For free-blowing units installed 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.

1.3.9.2. Ducted UD/HD/CD/RD units

These 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.

Ductwork must be specially calculated to comply with the

maximum static resistance available for the specific model installed. (see table)

If fitting horizontal ductwork, it is recommended that a plenum box with the same external dimension as the duct spigot with a minimum height of 1.0m be fitted to the heater outlet spigot to allow for even distribution of air.

If fitting vertical ductwork it is recommended that a plenum box with the same external dimension as the duct spigot with a minimum height of 1.0m be fitted to heater outlet spigot prior to any restriction in ductwork. 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.

Standard Motor LHP Motor

Model

CPx30 0.97 188 250

CPx45 0.86 222 250

CPx60 1.01 270 400

CPx90G 2.11 250 500

CPx90O 1.5 200 450

CPx120 2.3 180 350

CPx150 3 .15 185 400

CP x175 3.36 290 500

CPx200 3.84 250 500

CPx250 4.49 140 450

CPx300 5.76 150 500

page no. 26 of 68

Air Volume

(m³/s)

Max Duct

Resistance (Pa)

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Max Duct

Resistance (Pa)

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.

Page 27

2.1.1 Fitting space requirement

2.1 Fitting the Unit

Model 30 45 60 90 120 150 175 200 250 300

A Front mm 750 750 950 950 1250 1250 1450 1450 1650 1650

B Rear mm 1000

C Above mm 1000

D Side (Blank panel)* mm 150

E Side (Louvred)* mm 1000

To the front The depth of the heater 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

* Side panels are interchangeable to ease with installation against walls etc. Therefore D can = 1.0m if E = 0.15m OR E can = 0.15m if D = 1.0m

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 27 of 68

Page 28

2.1 Fitting the Unit

2.1.2. 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

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.

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. Gas Connection (where neccessary)

• 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.

2.1.3. Installing the 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 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.

NOTE: CPx 250 & CPx 300 heaters have louvred lower panels on both sides. The minimum clearance of 0.15m is increased to 0.5m.

NOTE: Smaller heaters are supplied with one blank side panel and one louvred side panel. If the heater is installed against a wall ensure

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

2.1.5. Oil Connection (where neccessary)

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

2.1.6 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.

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 section 2.5 or the accompanying wiring diagram.

page no. 28 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 29

2.2 Fitting the Flue

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 (1m for external EA units). 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 General Identification of Items

Air Outlet Turrets

Exhaust Flue

High Limit Reset

Water Drip Tray

Data Plate

Burner Lockout Reset

Burner

MC200 Controller

High Limit Indication

Electrical Connections (behind cover)

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 29 of 68

Page 30

2.4 Electrical Cable Installation

2.4.1. Electrical Connections

Warning: THIS APPLIANCE MUST BE

EARTHED.

Warning: Wiring external to the unit must be

carried out by an appropriately qualified

person to current IEE regulations for Electrical Installations and any local regulations which apply.

The local 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. Wiring should be completed in flexible conduit.

The local electrical supply conditions must be compatible with the electrical data given on the appliance data plate.

Heaters are for use with 230V, 1N, 50Hz or 400V, 3N, 50Hz supplies (see heater data plate).

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.

2.4.2. Typical Wiring Installation showing remote controller

Key: A = 2 core and earth (single phase) 4 core and earth (three phase) B* = MC200 On/Off = 5 core and earth MC200 High/Low = 7 core and earth MC200 Mod = 7 core and earth C= Screened 2 core (MC200 models only)** ** (screen must be grounded only at the MC200, See

instructions supplied with controller for wiring sizing, Max. 100m)

The method of connection to the main electricity supply must:-

- facilitate the complete electrical isolation of the heater(s) that will prevent remote activation of the heater during servicing.

- be in a readily accessible position adjacent to the heater(s).

- serve only the heater(s).

- have a contact separation of at least 3mm in all poles. See the wiring diagram for the heater electrical connections.

All units are fully prewired and only require final connections for the incoming mains supply. Heaters not supplied with inbuilt time and temperature controls will also require completion of the external control circuit (230V) via a room thermostat, time clock etc. and, if applicable, the remote low level lockout reset.

Reference must be made to Section 1.2 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.

Typical wiring

installation

Optional

Remote Controller

(MC200 shown)

Remote

Sensor

(optional)

Fused Isolator

230V Supply shown

(415V option on 120-300)

page no. 30 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 31

2.4.3. Wiring

2.4 Electrical Cable Installation

The wiring terminals, both mains input and controller, are located on the electrical chassis panel behind the bottom front panel of the heater which firstly has to be removed.

2.4.3.1. Mains Supply

1 phase

2.4.3.2. Intergral Control Wiring

Mains input of either 230V 50Hz 1Ph or 415V 50Hz 3Ph supply connections are via a separate terminal block. For input power refer to table below.

3 phase

The heater is fitted with an integral MC200/CAB controller which is pre-wired to the terminal strip

2.4.4. External Fuses

Model Pha

CPx30 1

CPx45 1

CPx60 1

CPx90G, CPx90O 1

Standard Motor

Fuse Rating (A)

6 6

10 6

6 16

16 16

V+

COM

SEN1

SEN2

Large Horsepower (LHP)

Fuse Rating (A)

CPx120, CPx150 3

CPx175, CPx200, CPx250 3

CPx300 3

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

10 10

10 16

16 32

page no. 31 of 68

Page 32

2.4 Electrical Cable Installation

1 Pha

Mains

Supplies

Mains

Supplies

3 Pha

(option

)

3 Pha

(option

)

2.4.5. Optional Remote Controller

The wiring terminals, both mains input and controller, are located on the electrical chassis panel behind the bottom front panel of the heater which firstly has to be removed.

Mains input of either 230V 50Hz 1Ph or 415V 50Hz 3Ph supply connections are via a separate terminal block. For input power refer to table below.

The mains supply ( single or three phase) connections are via a Hylec terminal block.

Control Circuitry connections are via a 30A numbered terminal strip. They are as follows:

terminal 7 230V Heat Demand terminal 8 230V Main Fan Only terminal 9 Lockout indication - 230V Output terminal 10* Burner reset - Neutral Switch

* only available with gas cabinets

NOTE:

To achieve maximum system efficiency it is recommended that CPx units are controlled

by an MC200 Fuel Saver unit. Simple room thermostat and thermostat/time clock control systems will not provide optimum system efficiency and fuel savings.

Wiring drawings and instructions are supplied with the respective controller.

to Heater

MC200

Terminals

CPx

Terminals

3 2 1

page no. 32 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 33

TITLE:

DRG NO:

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

CPxG / CPxO, 30-90, HI/LO, 1ph, Fitted MC200

(ERP Ph 1.0)

H02GBE0187

1New Drawing

MC200 fuelsaver Cabinet

POWRMATIC LTD

Powrmatic Ltd . Hort Bridge, Ilminster, Somerset

TA19 9PS TEL: 01460 53535 FAX:01460 52341

Web: www.powrmatic.co.uk E-Mail r&d@powrmatic.co.uk

This drawing is copyright and the property of POWRMA TIC

LIMITED. It must not be used without their knowledge, nor

communicted to any other person or company.

DRN

IA NO

DCR

DATE

MODIFICATIONS ISSUE

TITLE:

DRG NO:

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

Yel 0.5 Yel 0.5

CPxG / CPxO, 30-90, HI/LO, 1ph, Fitted MC200

(ERP Ph 1.0)

H02GBE0187

JMC --

22.12.17

1New Drawing

MC200 fuelsaver Cabinet

Unit

llo

l 0

2.5 Wiring Diagrams

2.5.1 CPx30-90 1Pha Gas/Oil Heater Main Internal Wiring Diagram

Unit

l 0

llo

ºc

5 Core

Cable

Blk 1.0

L N

RIELLO

GULLIVER

t1t

2 Core

t6t

Blk 0.75

Grey 0.75

Br 0.75

Blu 0.75

Link removed

by Powrmatic

Br 0.75

Blu 0.75

Gr/Yel 0.75

Cable

5 Core

Cable

Gry 1.0

Or 0.5

Br 1.0

Yel 1.0

COM

3 Core

Cable

Br 1.5

13 14

Br 1.5

11 12

6 7 8 9 10

Blu 0.5

Br 0.5

Gry 0.5

Yel 0.5

Br 0.5

COM

Blu 0.5

COM

654

Blu 0.5

Blk 0.5

Wh 0.5

231

R/S

TRP

NNN

LLL

LIVE

EARTH

NEUTRAL

COM

Blk 0.5

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

MAINS SUPPLY

230v 1ph 50Hz

page no. 33 of 68

Page 34

POWRMATIC LTD

Powrmatic Ltd . Hort Bridge, Ilminster, Somerset

TA19 9PS TEL: 01460 53535 FAX:01460 52341

Web: www.powrmatic.co.uk E-Mail r&d@powrmatic.co.uk

TITLE:

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

ºc

5 Core

Cable

4 Core

Cable

U V W

143100606

143100563

Model Specif ic

143000306

Model Specif ic

Gry 1.0

Blk 1.0

llo

Br 1.5

Blk 1.5

Grey 1.5

Gr/Yellow 1.5

CPxG / CPxO, HI/LO, 3ph, DOL, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

Unit

llo

l 0

Plug & socket on

split form heater s only

TITLE:

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

5 Core

Cable

4 Core

Cable

U V W

Br 1.5

Blk 1.5

Grey 1.5

Gr/Yellow 1.5

CPxG / CPxO, HI/LO, 3ph, DOL, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

Unit

llo

l 0

Plug & socket on

split form heater s only

TITLE:

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

CPxG / CPxO, HI/LO, 3ph, DOL, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

DCR

DATE

28.02.18

MODIFICATIONS ISSUE

TITLE:

DRG NO:

H02GBE0190

Items M&N added

Wiring Legend

Connections made by Contro l

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

CPxG / CPxO, HI/LO, 3ph, DOL, Fitted MC200

(ERP Ph 1.0)

2.5 Wiring Diagrams

2.5.2 CPx120-200 3Pha Gas/Oil Heater Main Internal Wiring Diagram

Unit

l 0

llo

ºc

RIELLO

GULLIVER

Grey 0.75

t2t

Blu 0.75

Blk 0.75

llo

t7t6b5t7t6

Br 0.75

Gr/Yellow 0.75

2 Core Cable

Link remov ed

by Powrmatic

Red 0.5

13 14

11 12

6 7 8 9 10

Yel 0.5

5 Core

Cable

Vi 0.5

Blu 0.5

COM

Yel 0.5

COM

Blk 0.5

Yel 0.5

Blu 0.5

R/S

Wh 0.5

Blk 1.0

Br 1.0

Yel 1.0

T3T2T1

L3L2L1

Br 1.5

Blk 1.5

Grey 1.5

Br 0.5

COM

654

Blu 0.5

Blk 0.5

Br 0.5

231

TRP

95 96

A1 A2

Blu 0.5

U V W

4 Core

Cable

555

4 44

3 33

2 22

1 11

LIVE 2

LIVE 3

LIVE 1

EARTH

NEUTRAL

MAINS SUPPLY

400v 3ph 50Hz

page no. 34 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 35

2.5 Wiring Diagrams

DRN

IA NO

DCR

DATE

JMC

28.02.18

MODIFICATIONS ISSUE

TITLE:

DRG NO:

H02GBE0193

Items N & O added

Wiring Legend

Connections made by Control

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

Gry 1.0

CPxG / CPxO, HI/LO, 3ph Soft-Start, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

Unit

llo

l 0

4 Core

Cable

U V W

Br 1.5

Blk 1.5

Grey 1.5

5 Core

Plug & sock et on

split form heaters only

TITLE:

DRG NO:

H02GBE0193

Wiring Legend

Connections made by Control

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

CPxG / CPxO, HI/LO, 3ph Soft-Start, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

IA NO

DCR

DATE

28.02.18

MODIFICATIONS ISSUE

TITLE:

DRG NO:

H02GBE0193

Items N & O added

Wiring Legend

Connections made by Control

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

CPxG / CPxO, HI/LO, 3ph Soft-Start, Fitted MC200

(ERP Ph 1.0)

POWRMATIC LTD

Powrmatic Ltd . Hort Bridge, Ilminster, Somerset

TA19 9PS TEL: 01460 53535 FAX:01460 52341

Web: www.powrmatic.co.uk E-Mail r&d@powrmatic.co.uk

This drawing i s copyright and th e property of POWR MATIC

LIMITED. It must not be used without their knowledge, nor

communicated to any other person or company.

DRN

IA NO

DCR

DATE

JMC

28.02.18

MODIFICATIONS ISSUE

TITLE:

DRG NO:

H02GBE0193

Items N & O added

Wiring Legend

Connections made by Control

board Assembler

Connections made by Final

Assembler

Connections made by

Installer

143100606

143100563

Model Specific

143000306

Model Specific

Blk 1.0

CPxG / CPxO, HI/LO, 3ph Soft-Start, Fitted MC200

(ERP Ph 1.0)

MC200 fuelsaver Cabinet

Unit

llo

l 0

4 Core

Cable

U V W

Br 1.5

Blk 1.5

Grey 1.5

Gr/Yellow 1.5

ºc

llo

Plug & sock et on

split form heaters only

2.5.3 CPx250-300 3Pha Gas/Oil Heater Main Internal Wiring Diagram

Unit

l 0

llo

Gr/Yellow 1.5

ºc

llo

Blk 1.0

Cable

5 Core

Cable

Gry 1.0

Br 1.5

Blk 1.5

Grey 1.5

U V W

4 Core

Cable

95 96

t7t6b5t7t6

s3NLt2t

Br 0.75

Blu 0.75

Blk 0.75

Grey 0.75

Gr/Yellow 0.75

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

2 Core Cable

Link removed

by Powrmatic

Red 0.5

13 14

Br 1.0

Yel 1.0

11 12

6 7 8 9 10

Yel 0.5

5 Core

Cable

Vi 0.5

Blu 0.5

Blk 0.5

COM

Yel 0.5

COM

Yel 0.5

Blu 0.5

R/S

Wh 0.5

Br 0.5

231

TRP

COM

654

Red 0.5

Blu 0.5

Blk 0.5

L2L3L1

Br 1.5

Blu 0.5

Blk 1.5

Grey 1.5

I-

Br 1.5

Blk 1.5

Grey 1.5

555

4 44

3 33

2 22

1 11

LIVE 1

LIVE 2

LIVE 3

EARTH

NEUTRAL

MAINS SUPPLY

400v 3ph 50Hz

page no. 35 of 68

Page 36

2.6 Commissioning and Testing

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed, adjusted and, if necessary, converted by qualified persons* in accordance with the

current issue 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.

* Gas Safe Registered Engineer

The CPx cabinet heater will be despatched preset and fully tested to our most up to date test procedures.

2.6.1. Electrical Installation

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

2.6.2. Gas Installation (where applicable)

For new installations, 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 (Edition 2) or IGE/UP/2A as appropriate.

2.6.5. Lighting The Heater

NOTE: The limit thermostat interlock relay may require resetting after loss of the electrical supply to the heater regardless of whether the

limit thermostat has operated.

2.6.5.1. 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.

IMPORTANT: 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.

2.6.5.1.1. Gas Controls Assembly - Soundness Check

1. Ensure the gas service valve at the inlet to the gas controls assembly is shut.

2.6.3. Oil Installation (where applicable)

The whole of the oil installation, including the tank, should be inspected and tested in accordance with the recommendations of OFTEC.

2.6.4. 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 section 1.2. 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. Conversely if the duct system resistance is greater than the available air pressure of the heater supplied the system resistance must be reduced.

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. If any adjustments have been made, re-check both high and low fire once more.

2.6.5.1.2. 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 and check that the following sequence of events occurs.

i) Burner fan runs. ii) Ignition spark is heard. iii) Main gas valves open and main gas flame is

established.

page no. 36 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 37

2.6 Commissioning and Testing

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

4. Switch OFF main electricity supply.

2.6.5.1.3. Final Adjustments

1. Remove the burner cover by undoing the two screws either side of the housing. (Gulliver burner shown)

2.6.5.1.3.1. Hi/Low Burners

1. Remove the sealing screw from the pressure test point located on the bottom 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.

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) Main gas valves open and main gas flame is established.

4. Check that the High Fire burner gas pressure agrees with that stated on the heater data plate and in section

1.2. If necessary adjust the high fire burner gas pressure by rotating the adjustment screw under the cover flap clockwise (+ positive), anticlockwise (- negative).

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. Clockwise (- negative) anti-clockwise (- positive)

5. Check that the Low Fire burner gas pressure agrees with that stated on the heater data plate and in section

2. Check that the gas pressure switch on the side of the gas valve is set to cut out below the minimum inlet gas pressure (app. 15mbar)

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

1.2. If necessary adjust the low fire burner gas pressure by rotating the adjustment wheel clockwise (- negative) anti-clockwise (- positive)

page no. 37 of 68

Page 38

2.6 Commissioning and Testing

If any adjustments have been made, re-check both high and low fire once more.

6. Gulliver burners are manufactured to EN 676 standard and fitted with a singular air pressure switch.

Turn the switch at the lowest setting. With the burner working at the required output, adjust the dial clockwise, increasing its value until the burner shuts down. Reduce the value by one set point, turning the dial anti-clockwise. Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.

7. Me as ure 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 CO2 reading as indicated in section 1.2 (±0.5)

2.6.5.2. Oil Fired Heaters

NOTE: Refer also to the burner instruction booklet supplied with the heater. This provides information on how to adjust the burner, system checks and fault finding detail.

IMPORTANT:

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.

2.6.5.2.1. 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. Remove the gauge connection plug located on the bottom right of the oil pump and attach an oil 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.

8. Turn OFF the burner, remove pressure gauge and refit sealing screw in pressure test point and flue sample point cover plug.

2.6.5.1.3.2. Modulation Burners

Refer to the burner instructions supplied with the heater.

2.6.5.1.4 Final Soundness Test

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.

2.6.5.1.5 Flame Safeguard

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

5. Turn ON the main electrical supply and check that the burner fan starts.

6. Note: This step is only for when a vent valve is being used.

Open the vent valve. When air free oil issues from the vent valve close the valve and the burner will fire when the ignition spark is present. (Note: This procedure may need to be repeated several times if the oil line cannot be purged of air within one ignition cycle. At the end of the 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.

page no. 38 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 39

2.6 Commissioning and Testing

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.

2.6.5.2.2. Final Adjustment

2.6.5.2.2.1. Hi/Low Burners

1. Ensure the oil gauge is connected. 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 flame is established.

2.6.5.2.2.1.1 CPxO30 to CPx175 inc

If any adjustments have been made, re-check both high and low fire once more.

2.6.5.2.2.1.2 CPx200 & CPx250 inc

Burner Pressure Adjustment

Gauge Connection

Low Fire Pressure Adjustment

High Fire Pressure Adjustment

Gauge Connection

Check that the High Fire burner pump pressure agrees with that stated on the heater data plate and in section

1.2. If necessary adjust the pump pressure by rotating the high fire adjustment screw clockwise (+ positive), anticlockwise (- negative)

Check that the Low Fire pump pressure agrees with that stated on the heater data plate and in section 1.2. If necessary adjust the pump pressure by rotating the low fire adjustment screw clockwise (+ positive), anticlockwise (- negative)

Hi/Low operation works on the basis that either a single or both nozzles are open. Check that the burner pump pressure agrees with that stated on the heater data plate and in section 1.2. If necessary adjust the pump pressure by rotating the burner adjustment screw clockwise (+ positive), anticlockwise (- negative)

If any adjustments have been made, re-check both high and low fire once more.

2.6.5.2.2.1.3 CPx300

Burner Pressure Adjustment

Gauge

Connection

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 39 of 68

Page 40

2.6 Commissioning and Testing

2.6.5.2.2.1. Hi/Low Burners cont.

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 CO2 reading as indicated in section 1.2 (±0.5)

4. Turn OFF the burner. Remove oil gauge and refit gauge connection plug, refit flue sample point cover plug.

2.6.5.2.2.2. Modulation Burners

Refer to the burner instructions supplied with the heater.

2.6.5.2.3. Final Checks

After making final adjustments check that there are no leaks on the oil pipework.

2.6.5.2.4 Flame Safeguard

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

2.6.7. Soft Start (CPx250 & 300 only).

Ensure that the soft start settings are nominally:-

Ramp Up - 8.2 Ramp Down - 0 Initial Torque - 2

NOTE: Adjustments are then made if necessary. Usually reducing the ramp up time is all that is required. Avoid coming below 5 to ensure a low starting current.

2.6.8. Handing Over The Air Heater

2.6.6. Fan/Limit Stat

Ensure that the limit settings are as follows:Thermostat settings:-

Fan Off: 86°F/30°C Fan On: 122°F/50°C Limit: CPx 30 - 90, 150 - 175 212°F/100°C

CP x 120 230°F/110°C CPx 200 - 300 248°F/120°C

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 (or oil) connections and electricity supplies and leave instructional literature with the heater.

On ducted units ensure that the main air fan comes on no later than 150 to 180 seconds after the main burners light.

page no. 40 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 41

2.7 Servicing

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed,

adjusted and, if necessary, converted by

qualified persons* in accordance with the

current issue 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 safe register.

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

components.

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

2.7.1. General

section 2.6.6.4 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.

Full maintenance should be undertaken not less than once per year by a qualified person.

No 'specialised' tools will be required to carry out this service.

A fault finding guide is given in section 3.1 to aid servicing

After any servicing work has been complete, or any component replaced, the air heater(s) must be fully commissioned and tested for soundness as described in Section 2.6.

2.7.2. Main Burner Assembly Removal

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.

2.7.4. Main 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

2.7.5. 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.

2.7.3. 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

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

4. Reconnect the new valve in the reverse order to that above ensuring that the valve is correctly orientated. Renew the sealing 'O' rings if necessary.

page no. 41 of 68

Page 42

2.7 Servicing

2.7.6. Replacement of Faulty Components

2.7.6.1 Burner Components

Refer to the burner instructions supplied with the heater for information regarding replacement of individual components within the burner.

2.7.6.2 Complete Burner Set-up

If a burner has been replaced or substituted complete, the burner must be set up correctly.

2.7.6.2.1 BSD (Gas) for CPxGO30 to CPxG175 inc

1. Remove the burner cover by undoing the two screws either side of the housing.

Adjustment of the first stage air damper position is carried out by setting the air damper motor.

2. Loosen locknut (clockwise) and adjust by turning screw to the required setting as indicated on the adjacent scale. Once the setting is achieved, tighten locknut (anticlockwise). (When the burner stops, the air damper closes automatically under its own weight)

Head pressure is achieved by adjusting a screw which moves a regulating rod. A test point on the burner casting allows reading the air pressure in the combustion head.

4. Rotate the setting screw in a clockwise or anticlockwise direction until set point marked on the regulating rod is level with the outside plane of the head assembly.

Gulliver burners are manufactured to EN 676 standard and fitted with a singular air pressure switch.

5. Turn the switch at the lowest setting. With the burner working at the required output, adjust the dial clockwise, increasing its value until the burner shuts down. Reduce the value by one set point, turning the dial anti-clockwise.

Adjustment of the second stage air damper position is carried out by setting the air damper indicator.

3. Slightly loosen locknut (clockwise) and adjust by turning screw till the required setting is shown level with the locknut. Once the setting is achieved, tighten locknut (anticlockwise) (may require re-adjust when the nut is locked down).

page no. 42 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

6. Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.

Page 43

For adjustment and setting of gas valve, refer to section

2.6.5.1.3

Correct operational start-up 0s Start of heat demand. Burner begins the ignition cycle. 0s-4s The burner is in stand-by. 4s-44s Pre-purge with opened air damper 44s Ignition 1st stage. 49s-69s Ignition 2nd stage.

2.7.6.2.2 RSD (Gas) for CPxG200 to CPxG250 inc

2.7 Servicing

III

Head pressure is achieved by adjusting a screw which moves a regulating rod. A test point on the burner casting allows reading the air pressure in the combustion head.

1. Remove the burner cover by undoing the two screws either side of the housing.

Adjustment of the first and second stage air damper position is carried out by setting the cam on the servomotor.

2. Remove the plastic cover.

3. Use a flat-headed screwdriver to adjust the air damper cam settings. This allows you to make small adjustments to the air damper. As you turn the screw, the numbers will rotate.

5. Rotate the setting screw in a clockwise or anticlockwise direction until set point marked on the regulating rod is level with the outside plane of the head assembly.

Gulliver burners are manufactured to EN 676 standard and fitted with a singular air pressure switch.

6. Turn the switch at the lowest setting. With the burner working at the required output, adjust the dial clockwise, increasing its value until the burner shuts down. Reduce the value by one set point, turning the dial anti-clockwise.

7. Check for reliable burner operation, if the burner shuts down, reduce the value by a half set point.

4. Read off numbers against the red line marker point (indicated opposite)

FIRST STAGE ADJUSTMENT

By adjusting the micrometric screw, cam I regulates the position of the 1st stage air damper (default value 25°).

SECOND STAGE ADJUSTMENT

Cam II regulates the position of the 2nd stage air damper (factory setting reference value 50°, do not exceed 65°).

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

For adjustment and setting of gas valve, refer to section

2.6.5.1.3

page no. 43 of 68

Page 44

2.7 Servicing

Correct operational start-up 0s Start of heat demand. Burner begins the ignition cycle. 0s-4s The burner is in stand-by. 4s-44s Pre-purge with opened air damper 44s Ignition 1st stage.

47s-52s Ignition 2nd stage.

2.7.6.2.2 RGD (Oil) for CPxG30 to CPxG250 inc

1. Remove the burner cover by undoing the two screws either side of the housing.

Head pressure is achieved by adjusting a screw which moves a regulating rod. A test point on the burner casting allows reading the air pressure in the combustion head.

4. Rotate the setting screw in a clockwise or anticlockwise direction until set point marked on the regulating rod is level with the outside plane of the head assembly.

Adjustment of the first stage air damper position is carried out by setting the air damper.

2. Loosen locknut (clockwise) and adjust by turning screw to the required setting as indicated on the adjacent scale. Once the setting is achieved, tighten locknut (anticlockwise).

Adjustment of the second stage air damper position is carried out by setting the air damper indicator.

5a. CPx 30 - CPx 175 ONLY High Fire pump pressure is adjusted by rotating the high fire adjustment screw clockwise (+ positive), anticlockwise (- negative). Low Fire pump pressure is adjusted by rotating the low fire adjustment screw clockwise (+ positive), anticlockwise (- negative).

Correct operational start-up 0s Start of heat demand. Burner begins the ignition cycle. 0s-12s Pre-purge with opened air damper 12s Ignition 1st stage. 15s-40s Ignition 2nd stage.

page no. 44 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 45

2.7 Servicing

5b. CPx 200 - CPx 250 ONLY Hi/Low operation works on the basis that either a single or both nozzles are open. Adjust the pump pressure by rotating the burner adjustment screw clockwise (+ positive), anticlockwise (- negative)

RG1RKD-RG4D Pumps

LOW FIRE ADJUSTMENT

HIGH FIRE ADJUSTMENT

6. Re-check If any adjustments have been made.

RG5D Pump only

HIGH

FIRE

ADJUSTMENT

2.7.6.3. Gas Controls Assembly (if applicable)

terminal strip - see section 2.5 or the accompanying wiring diagram.

3. Remove the two screws, one on each side of the fan mounting flange, that secure the fan to the fan shroud.

4. Remove the screws securing the heat exchanger mounting frame to the fan shroud on the side that the fan is going to be withdrawn.

5. Withdraw the fan from the slide rails.

6. Reassemble in reverse order.

2.7.6.4.1. CPx 150 - CPx 300

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

1. Remove the lower panels of the heater to gain access to the fan section.

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.

2.7.6.4. Main 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

2.7.6.4.1. CPx 30 - CPx 120

2. Release the motor mounting plate securing screws and then remove the belt tension by turning the tension adjustment screw anticlockwise. 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.

NOTE: These heaters are fitted with direct drive fan units.

1. Remove the lower panels of the heater to gain access to the fan section.

2. Disconnect the fan motor electrical leads from the

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 45 of 68

Page 46

2.7 Servicing

2.7.6.5. Fan/Limit Thermostat

NOTE: CD/CF Counterflow heaters have two fan and limit thermostats fitted. Either one will start the main fan and either one will shut the burner down in the event of an overheat

situation.

Mechanical Limiter

Release Point

Fan OFF Set Point Adjuster

Fan Circuit

OUT

Fan ON

Override

Fan Circuit

Fan ON

Set Point

Adjuster

T I O N

A U

DO N OT RO TAT E - HOLD

DIAL WHEN SETTING POINTER

Brass Link

Location

1. Undo cover retaining screw

Set Point Dial

Mechanical

Limiter

NOTE: The new L4064B may be supplied with the limit temperature mechanically limited to

Limit Set

Point

Adjuster

Limit Circuit

OUT

small hole at the top of the dial located by the word "CAUTION". At the same time prevent the dial from rotating and push the limit temperature adjuster around to the required setting.

less than the setting required. To release the mechanical limit push a stiff wire into the

CAUTION

Limit Circuit

2. Squeeze the sides of the cover and remove cover by pulling forward.

3. Release wiring from clamp terminals by pushing a small screwdriver into the clamp release holes adjacent to the clamps.

4. Remove the 2 screws securing the thermostat to the heater panel and withdraw thermostat.

5. Reassemble new unit in reverse order referring to the heater wiring diagram to ensure correct wiring as detailed in section 2.5.

IMPORTANT: A replacement fan/limit thermostat may have a brass link between the terminals. This MUST be removed, before the replacement thermostat is installed.

Thermostat settings:-

Fan Off: 86°F/30°C Fan On: 122°F/50°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: Temperature points on the dial are in Fahrenheit

page no. 46 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 47

3.1.1. Heater General

Fault Action

1. Check electrical supply is ON.

2. Check controls are ON or calling for heat.

Heater does not turn on

Heater goes into high limit trip

Main fan runs continuously

Main fan fails to run

3. Faulty burner control unit.

4. Limit thermostat open circuit/faulty, interlock relay not set/faulty.

5. Check fuel supply is present.

1. Faulty or incorrect setting fan thermostat - See Section 2.6.6

2. Faulty or incorrect setting limit thermostat - See Section 2.6.6

3. Faulty fan assembly - change.

4. Fan motor out on thermal overload/inbuilt motor thermal trip.

- check running amps. See section 1.2

- check duct resistance. See duties, page 7

- check that airflow through the heater is not restricted.

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

2. Summer/Winter switch set to Summer - set to Winter.

3. Faulty or incorrect setting fan thermostat - See Section 2.6.6

1. Fan motor or capacitor failed - replace.

2. Fan thermostat faulty - replace.

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

4. Reset Motor Overload

3.1 Fault Finding

3.1.1.1 BSD/RSD (Gas) for CPxGO30 to CPxG250 inc

Indication of operation

In normal operation, the various statues are indicated in the form of colour codes according to the table below.

Diagnosis of fault causes

After lock-out has occurred, the red signal lamp is steady on. The control box has a diagnostic function that can identify the likely causes of any malfunctions (indicator: RED LED). In order to be able to use this function, press and hold the reset button for at least 3 seconds from when the appliance is made safe (lock-out). The control box sends a sequence of pulses that are repeated at 2-second intervals.

Blink code Possible cause of fault 2 blinks No flame at the end of safety time: faulty or soiled gas valves.

faulty ionisation probe. poor adjustment of burner, no gas. faulty ignition transformer. neutral / phase exchange. _______________________________________ 3 blinks Air pressure switch does not close or is already closed before heat demand: faulty air pressure switch. air pressure switch incorrectly regulated. _______________________________________ 4 blinks Presence of flame (light) in chamber: in stand-by position. with thermostat of heat demand in idle or working position. during pre-purge. during post-purge. _______________________________________ 6 blinks Loss of air pressure: during pre-purge. during or after safety time. _______________________________________ 7 blinks Loss of flame during operations after 3 attempts of re-cycle: faulty or soiled gas valves. faulty ionisation probe. short circuit between ionisation probe and earth of the burner. poor adjustment of burner, no fuel

To reset the control box after the diagnostics display, press the lockout-reset button.

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 47 of 68

Page 48

3.1 Fault Finding

FAULTS POSSIBLE CAUSES SOLUTION

Check presence of voltage in the L1-N clamps of the 7 pin plug.

Check the condition of the fuses.

Check that safety thermostat is not lock out.

Check the manual cock opening

Check that the valves charge over to the opening position and there are not short circuits.

Adjust them.

Check and connect all the plugs

Replace the pressure switch

Restore correct maximum ratio of 1:2, making sure 1st stage output is no less than the operating range’s minimum.

Check the right position and if necessary set it according to the instructions.

Reset the electrical connection.

Replace the faulty connection.

Adjust it.

Check the right working.

Check the right electrical connection

Failed valve: replace it.

The air damper doesn’t close completely and therefore it doesn’t pull in the 2nd stage valve micro: check the micro working.

Check the pressure in the network and/or adjust the solenoid valve according to the instructions of this manual.

Check the right insertion of the connectors.

Check the right position of the electrode according to the instructions of this manual.

The pressure switch is faulty, change it.

The air pressure is too low, (the head is bad adjusted).

Lower and set the pressure switch.

The burner doesn’t start when the limit thermostat closes.

Burner tends to pull the ﬂame when switching from 1st to 2nd stage.

The burner runs normally in the prepurge and ignition cycle and locks out after about 3 seconds.

The burner starts with an ignition delay.

The burner doesn’t change over the 2nd stage.

The burner locks out after the prepurge phase due to ﬂame failure.

The burner locks out during the prepurge phase.

The burner continues to repeat the starting cycle without going on lock-out.

Lack of electrical supply.

Lack of gas

The gas pressure switch does not close its contact.

The connections in the control box are wrongly inserted.

The air pressure switch is changed over to the operational position.

Output ratio between 1st and 2nd stage greater than 1:2.

High air excess in 1st stage Restore the correct air excess value (λ min. = 1.3) see manual

Phase and neutral connection is inverted. Invert them.

The earth connection lacks or is ineﬃcient. Make the earth connection eﬃcient.

The ionization probe is earthed or not in contact with the ﬂame, or its wiring to the control box is broken, or there is a fault on its insulation to the earth.

The ignition electrodes is wrongly positioned. Adjust it according to the instructions.

Air output is too high. Set the air output according to the instructions.

Valve brake is too close with insuﬃcient gas output.

The air damper is locked.

The 2nd stage gas valve doesn’t pull in.

The solenoid valves is passing too little gas.

The solenoid valves are defective. Change them

The ignition arc is irregular or has failed.

The pipe has not been purged from the air. Carry out a complete breathing of the line of gas-supply.

The air pressure switch does not change over to the operational position.

The ﬂame exists. Faulty valves: replace them.

The pressure test point is badly positioned. Place it in the right position according to the instructions.

The gas pressure in the gas main lies very close to the value to which the gas pressure switch has been set. The sudden falling oﬀ pressure at the opening of the valve causes the opening of the pressure switch. However this only temporarily, because the valve immediately closes again, so then does the pressure switch, because the pressure builds up again, causing the cycle to be repeated over and over.

page no. 48 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 49

3.1.1.2 BSD/RSD (Gas) for CPxGO30 to CPxG250 inc

Lock-out due to ignition failure

If the flame does not light within the safety limit (~ 5s) the burner locks-out. Lock-out is shown by a led on the appliance. MAXIMUM Total number of recycle trials is 3. To carry out the control box reset, proceed as follows: Press the reset button for at least 1 second. In the event of the burner not restarting it is necessary to check if the limit thermostat (TL) is closed.

FAULTS POSSIBLE CAUSES SOLUTION

Check presence of voltage in the L1 - N clamps of the 7 pin plug.

Check the conditions of the fuses.

Check that thermostat limit is not

lock out.

Check and connect completely all the plugs.

Check pressure and output of the fuel.

Check air output.

Change nozzle.

Check the coil of solenoid valve 1st stage.

Adjust them according to the instructions of this manual.

The burner will not start when the adjustment thermostat closes.

Burner runs normally in the prepurge and ignition cycle and locks out after 5 seconds ca.

Burner starts with an ignition delay.

Lack of electrical supply.

The photoresistance sees false light. Eliminate the light.

Heater and start thermostats are faulty. Replace them.

The connections in the control box are wrongly inserted.

The photoresistance is dirty. Clear it.

The photoresistance is defective. Change it.

Flame moves away or fails.

The ignition electrodes are wrongly positioned.

Air output is too high. Set the air output according to the instructions of this manual.

Nozzle dirty or worn. Replace it.

3.1 Fault Finding

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 49 of 68

Page 50

3.2 List of Parts

Item Description CPx30 CPx45 CPx60 CPx90 CPx120

Riello Gas Burner NatGas c/w Valve & Lead

Gas Valve

Burner Gasket Gas Oil

Riello 35s Oil Burner c/w Nozzle & Lead

Nozzle 35 sec 28 sec

BNR030CPxG

/MK3/ERP

14292110 14292111 14292112

14193708 1 141937080

BNR030CPxO

/MK3/ERP

14152105 9

141522 381

BNR045CPxG

/MK3/ERP

14193708 1

141930806

BNR045CPxO

/MK3/ERP

141522 600 141522 610

BNR060CPxG

/MK3/ERP

141930806 141930806

BNR060CPxO

/MK3/ERP

141522 610 141522 620

BNR090CPxG

/MK3/ERP

141937150 141937150

BNR090CPxO

/MK3/ERP

141522 629 141522 66 3

BNR120 CP xG

/MK3/ERP

BNR120 CP xO

/MK3/ERP

141522 661 141522 670

Oil Filter

Fire Valve

Fan & Limit Thermostat L4064

Limit Interlock P.C.B. MkIII

Fuse

Standard LPH

140700046 140700046

141474534

141474530

143000306

1424 03600/3

140700040

n/a

140700042

140700042*

n/a n/a

LPG Conversion Kit

page no. 50 of 68

CPX30HL/LPG CPX45HL/LPG CPX60HL/LPG CPX90HL/LPG CPX120HL /LPG

* n/a on LHP CPx90 Gas

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 51

3.2 List of Parts

Item Description CPx150 CPx175 CPx200 CPx250 CPx300

Riello Gas Burner NatGas c/w Valve & Lead

Gas Valve

Burner Gasket Gas Oil

Riello 35s Oil Burner c/w Nozzle & Lead

Nozzle 35 sec

28 sec

BNR150CPxG

/MK3/ERP

141937150 141937150

BNR150CPxO

/MK3/ERP

141522 670

1415227 04

BNR175CP xG

/MK3/ERP

14292113 14292114 14292105

BNR175CP xO

/MK3/ERP

1415227 04

141522 82 0

BNR200CPxG

/MK3/ERP

14193708 2

141937150

BNR200CPxO

/MK3/ERP

141522 659+

141522 629

141522 659+

141522 670

BNR250CPxG

/MK3/ERP

BNR250CPxO

/MK3/ERP

141522 659+

141522 670

1415227 03+

141522 670

BNR300CPxG

/HILO/MK3

142992790 142992790

BNR300CPxO

/HILO/MK3

141522661+

1415227 06

14152350 0

Oil Filter

Fire Valve

Fan & Limit Thermostat L4064

Limit Interlock P.C.B. MkIII

Fuse

Standard LPH

141474534

141474530

142403609

142403603

n/a n/a

LPG Conversion Kit

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

CPX150HL/LPG CPX175HL/LP G CPX200HL/LPG CPX250HL/LPG CPX300HL/LPG

page no. 51 of 68

Page 52

3.2 List of Parts

Item Description CPx30 CPx45 CPx60 CPx90 CPx120

HTX Gas Oil

Swirlers Gas Oil

CPx0450201 CPx0450201

n/a n/a

CPx0450202 CPx0450201

28 x CPx0900223

n/a

CPx0600201 CPx0600202

34 x CPx0900223

n/a

CPx0900201 CPx0900202

34 x CPx1500223 17 x CPx0900223

CPx1200201 CPx1200202

23 x CPx1500223

n/a

MC200 Controller

Control Panel

Std On/Off

20mm x 3mm Plain Tape Gasket

10mm x 3mm Sponge Strip Gasket

Burner Mtg Gasket

HTX Cleanout Gasket

CPX3-90/CP/

MK3

1.25 x

142206504

CPxSTD00301 CPxSTD00302

CPX3-90/CP/

MK3

1.4 x

142206504

142203802 142203704

MC200CAB

CPX3-90/CP/

MK3

6m x 170272210

1.6 x 142206504 2 x 142206504

CPX3-90/CP/

MK3

CPX12-175/CP/

MK3

Flex Oil Line

Control Box Gas Oil

Motor

Fan Impellor

page no. 52 of 68

14195 6 0 87

141979 503 141979 501

141979 571 141979572

141979 5 81 141979582

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

141979 503 141979 502

Page 53

3.2 List of Parts

Item Description CPx150 CPx175 CPx200 CPx250 CPx300

HTX Gas Oil

Swirlers Gas Oil

CP x1500201

CPx1500202

46 x CPx1500223 23 x CPx1500223

CPx1750201 CPx1750202

29x CPx1750223

n/a

CPx2000201 CPx2000202

59 x 1750223 29 x 1750223

CPx3000201 CPx3000202

59 x 3000223 29 x 1750223

CPx3000201 CPx3000202

59 x 3000223

29 x 1750223

MC200 Controller

Control Panel

Std On/Off

20mm x 3mm Plain Tape Gasket

10mm x 3mm Sponge Strip Gasket

Burner Mtg Gasket

HTX Cleanout Gasket

CPX3-90/CP/

MK3

2.0 x

142206504

MC200CAB

CPX3-90/CP/

MK3

6m x 170272210 7m x 170272210

142203804 142203320

CPX3-90/CP/

MK3

3.0 x 142206504

CPxSTD00302

CPX3-90/CP/

MK3

CPX12-175/CP/

MK3

Flex Oil Line

14195 6 0 87 1419 56 012

Control Box Gas Oil

141979 503 141979 502

141979 503 141979 505

Motor Gas Oil

141979 572 141979 572

141979 573 141979 572

141979 573 141979 573

Fan Impellor Gas Oil

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

141979582 141979582

141979 5 83 141979582

141979 5 83 141979 5 83

142992997 142992650

142917808 142917808

142917821 141979 5 84

page no. 53 of 68

Page 54

3.2 List of Parts

Item Description CPx30 CPx45 CPx60 CPx90 CPx120

Electrode Gas

Sensor Probe

Gas

Photocell Oil

Electrode Oil

HT Lead Gas Oil

142992991 142992990

142992989 142992987

141979 531

142924310 142924311

142992998 142992999

Probe Lead

Speed Gear Pump

Coil 1 Coil 2

Pressure Switch

Capacitor

Hydraulic Ram

142992986

141979 551

141979 561 141979 56 2

145604651 14296110 8

141979 575

141979 591

141979 575 141979576

Damper Motor

page no. 54 of 68

141979 592

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 55

3.2 List of Parts

Item Description CPx150 CPx175 CPx200 CPx250 CPx300

Electrode Gas

Sensor Probe

Gas

Photocell Oil

Electrode Oil

HT Lead Gas Oil

142992990 142992988 14197910 4

142992987 142992894

141979 531 141979533 141979 532

142924311 142992793

142992998 142992999

142992998 142993000

142993001 142993002

Probe Lead

Speed Gear Pump

Coil 1 Coil 2

Pressure Switch

Capacitor Gas Oil

Hydraulic Ram

141979 551 141979 552 142992633

141979 561 141979 56 2

141979 575 141979576

142992986 145604654

1429 61108 142961106

141979 577 141979576

141979 591 142992813

141979 56 3

n/a

141979 577 141979 577

142992666

n/a

141979 578 141979 578

Damper Motor

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

141979 592 141979593 142992780

page no. 55 of 68

Page 56

3.2 List of Parts

Item Description CPx30 CPx45 CPx60 CPx90 GAS

DD Fan

Standard LPH

Main Fan

Standard LPH

Motor

Standard LPH

Motor Pulley

Standard LPH

1402CFAN150/T/15

n/a

1402CFAN240/T

n/a

140001520

n/a

142000602

1402CFAN140/T/15

n/a

1402CFAN240/T

n/a

140001520

n/a

142000602

1402CFAN210/T/15

n/a

1402CFAN510/T

n/a

140001998

n/a

142001689

n/a n/a

1402CFAN510/T 1402CFAN510/T

140001908 140001998

142001689 142001675

Motor T/lock

Standard LPH

Fan Pulley

Standard LPH

Fan T/lock

Standard LPH

Belts

Standard LPH

JOX Relay

Contactor

Standard LPH

n/a

142003350

n/a

142001689

n/a

142003370

n/a

142111504

143000816 143000816 143000816 143000816

n/a n/a

n/a

142003350

n/a

142001675

n/a

142003370

n/a

142111504

n/a n/a

n/a

142003360

n/a

142002604

n/a

142201225

n/a

142116903

n/a

143000601

142003360 142003360

142002604 142002604

142201225 142201225

142116903 142116903

n/a

143000601

Overload

Standard LPH

Soft Start

Standard LPH

page no. 56 of 68

n/a n/a

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

n/a n/a

n/a

143000800

n/a n/a

n/a

143000800

n/a n/a

Page 57

3.2 List of Parts

Item Description CPx90 OIL CPx120 CPx150 CPx175

DD Fan

Standard LPH

Main Fan

Standard LPH

Motor

Standard LPH

Motor Pulley

Standard LPH

Motor T/lock

Standard LPH

Fan Pulley

Standard LPH

1402CFAN560/

T/15

n/a

1402CFAN510/T

n/a

140001908

n/a

142001689

n/a

142003360

n/a

142002604

1402CFAN580/

T/15/3P

n/a

1402CFAN820/T

n/a

140002055

n/a

142000602

n/a

142003856

n/a

142001825

n/a

tba

1402CFAN820/T 1402CFAN820/T

140002055 140002108

142000602 142000601

142003856

142161028

142001825 142001825

n/a tba

1402CFAN820/T 1402CFAN820/T

140002108 140002206

142000602 142000602

142003856 142003856

142001689 142001619

Fan T/lock

Standard LPH

Belts

Standard LPH

JOX Relay

Contactor

Standard LPH

Overload

Standard LPH

Soft Start

Standard LPH

n/a

142201225

n/a

142116903

143000816 143000816 143000816 143000816

n/a n/a

n/a

142201225

n/a

142119742

143000601 143000601

143000802 143000802

n/a n/a

142201225

142003370

142119742 142119742

143000601 143000601

143000802 143000801

n/a n/a

142003370 142003370

142119730 142119730

143000601 143000601

143000801 143000828

n/a

143000620

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 57 of 68

Page 58

3.2 List of Parts

Item Description CPx200 CPx250 CPx300

DD Fan

Standard LPH

Main Fan

Standard LPH

Motor

Standard LPH

Motor Pulley

Standard LPH

n/a n/a

1402CFAN820/T 1402CFAN820/T

140002108 140002206

142000602 142000601

n/a n/a

1402CFAN510/

T/2DECK

140002108 140002206

142001619

142001689

n/a n/a

1402CFAN510/

T/2DECK

140002251 140002610

142001619 142001013

Motor T/lock

Standard LPH

Fan Pulley

Standard LPH

Fan T/lock

Standard LPH

Belts

Standard LPH

JOX Relay

Contactor

Standard LPH

142003856 142003655

142001619 142001619

142003370 142003370

142119730 142119730

143000816 143000816 143000816

143000601 143000601

142161028

142003655

142002604 142002604

142201225 142201225

142119742 142119742

n/a n/a

142003655

142201242

142002494 142001823

142201225 142201225

142119730 142119725

n/a n/a

Overload

Standard LPH

Soft Start

Standard LPH

page no. 58 of 68

143000801 143000828

n/a

143000620

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

143000801 143000828

n/a

143000620

143000800 143000807

143000621 143000621

Page 59

3.3 Fuel Conversion

3.3.1. Oil Conversion

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

We recommend that any adjustment or conversion should to be conducted by a competent person. It is in your own interests and that of safety to ensure that this is adhered to.

* A competent person such as an Oftec approved

Heater conversion between oil fuels will require a change of burner nozzle, adjustment of burner pressure and re-commissioning of the heater. (Refer to section 2.6 for commissioning details.)

Ensure that the oil inlet pressure to the heater does not exceed the maximum pressure stated in the burner manual, and that the oil line has been purged of the old oil.

3.3.1.1. Burner Nozzle Conversion

7. Refit all other components in reverse order.

8. Check that fitted fire valves are open.

9. 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.

10. Set the time clock and thermostat to call for heat or complete the external control circuit.

11. Turn ON the main electrical supply, press the limit reset switch if required and check that the burner fan starts.

3.3.1.2. Oil Pressure Settings

All burners used on the OUH range have oil pumps that may be set to operate on 35sec (diesel) and 28sec (kerosene).

Burner setting pressures are carried out by adjusting the high and low burner pressures to the value in the tables opposite.

Note*: Ensure the original data badge is removed and replaced with new data badge

1. Remove the burner from the heater and hook the burner to the flange.

2. Undo the fixing screws retaining the blast tube and remove.

3. Remove the cables from the electrode assembly.

4. Undo the fixing screws retaining the diffuser disc holder assembly from the nozzle holder assembly and remove.

5. Using appropriate spanners, hold the base of the nozzle holder whilst un-doing and removing the original nozzle.

3.3.1.3. High/Low Pump Adjustment

1. Ensure the oil gauge is connected. 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 flame is established.

CPx30 to

CP x175 inc

Low Fire Pressure Adjustment

High Fire Pressure Adjustment

6. Fit replacement nozzle, again by holding the base of the nozzle holder with a spanner whilst tightening nozzle.

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Gauge Connection

page no. 59 of 68

Page 60

3.3 Fuel Conversion

Check that the High Fire burner pump pressure agrees with that stated on the heater data plate and in section

1.2. If necessary adjust the pump pressure by rotating the high fire adjustment screw clockwise (+ positive), anticlockwise (- negative)

If any adjustments have been made, re-check both high and low fire once more.

CPx200 & CPx250 inc

2.6.5.2.2.1. Hi/Low Burners cont.

4. Turn OFF the burner. Remove oil gauge and refit gauge connection plug, refit flue sample point cover plug.

Burner Pressure Adjustment

Gauge Connection

If any adjustments have been made, re-check both high and low fire once more.

Burner Pressure Adjustment

CPx300

page no. 60 of 68

Gauge

Connection

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 61

3.3 Fuel Conversion

Riello Burner Settings - 28sec Oil - Kerosene - Net CV (Hi = 47.00MJ/kg)

Maximum Pump Suction = 0.4bar Burner Pressure

High Fire Low Fire

MODEL Nozzle Type

CPx30 0.75 x 60S CPX30HL/28 10.0 145 7.0 101.5

CPx45 1.25 x 60S CPX45HL/28 10.0 145 7.0 101.5

CPx60 1.50 x 60S CPX60HL/28 10.0 145 7.0 101.5

CPx90 2.50 x 60S CPX90HL/28 10.0 145 7.0 101.5

CPx120 3.00 x 60S CPX120HL/28 10.0 145 7.0 101.5

CPx150 3.75 x 60B CPX150HL/28 10.0 145 7.0 101.5

CP x175 4.50 x 60B CPX175HL/28 10.0 145 7.0 101.5

CPx200 2.5 + 2.0 x 60S CPX200HL/28 10.0 145 10.0 101.5

CPx250 3.5 + 3.0 x 60S CPX250HL/28 10.0 145 10.0 101.5

CPx300 tbc CPX300HL/28 tbc tbc tbc tbc

Kit part number

bar p.s.i. bar p.s.i.

Riello Burner Settings - 35sec Oil - Diesel - Net CV (Hi = 42.69MJ/kg)

Maximum Pump Suction = 0.4bar Burner Pressure

High Fire Low Fire

MODEL Nozzle Type

CPx30 0.75 x 60S CPX30HL/35 13.44 195 8.96 130

CPx45 1.25 x 60S CPX45HL/35 14.48 210 8.96 130

CPx60 1.50 x 60S CPX60HL/35 14 .13 205 8.96 130

CPx90 2.50 x 60S CPX90HL/35 13.79 200 8.27 120

CPx120 3.00 x 60S CPX120HL/35 12.07 175 8.96 130

CPx150 3.75 x 60B CPX150HL/35 15 .17 220 8.96 130

CP x175 4.50 x 60B CPX175HL/35 15 .17 220 8.27 120

CPx200 2.5 + 2.0 x 60S CPX200HL/35 13.10 190 13 .1 190

CPx250 3.5 + 3.0 x 60S CPX250HL/35 11.70 170 13 .1 190

CPx300 tbc CPX300HL/35 tbc tbc tbc tbc

Kit part number

bar p.s.i. bar p.s.i.

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 61 of 68

Page 62

3.3 Fuel Conversion

3.3.2. Gas Conversion

Gas Safety (Installation & Use) (Amendment) Regulations

It is law that all gas appliances are installed, adjusted and, if necessary, converted by qualified persons* in accordance with the

current issue 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.

* Gas Safe Registered Engineer.

3.3.2.1. General

Heater conversion between gases will require a change of burner injectors, alteration of burner pressure and re-commissioning of the heater. (Refer to section 2.6 for commissioning details.)

Ensure that the gas inlet pressure to the

heater is correct for the new gas, and that the

gas supply has been purged of the old gas.

(Refer to tables opposite for new gas inlet

pressures.)

3. Unscrew and remove the screws (5), pull out the head assembly support (6) turning it slightly to the right, taking care not to change the setting position on the elbowbracket during dismantling.

4. Remove the Natural Gas Injector Head by removing two screws.

5. To reassemble the new Injector head follow the above instructions in reverse, returning the head assembly (1) to its original position.

WARNINGS

• Tighten the screws (5) completely (without locking them); then lock them with a torque wrench setting of 3-4 Nm.

• Check there are no gas leaks from the screws during these operations.

• If the pressure test point (7) should work loose, it must be correctly fixed ensuring that the hole inside the head assembly (1) is facing downwards.

3.3.2.3. Gas Valve Settings

3.3.2.2. Burner Conversion

All gas valves used on the CPXx range have pressure regulators that may be set to operate on natural gas or propane (LPG).

Conversion is carried out by adjusting the high and low burner pressures to the value in the tables opposite.

(Refer to full regulator adjustment in section 2.6.6.1)

Note*: Ensure the original data badge is removed and replaced with new data badge and "change of gas" stickers.

High Fire

Regulator

Adjustment

1. Disconnect the probe connections (1 and 2).

2. Remove the small tube (3) and loosen the screws (4).

page no. 62 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

High Fire Fine Pressure Adjustment

Low Fire

Pressure

Adjustment

Page 63

3.3 Fuel Conversion

Natural Gas to Propane (LPG) Conversion Data

Nominal Inlet Pressure = 37mbar, Minimum Inlet Pressure = 37mbar Burner Pressure

High Fire Low Fire

MODEL

CPx30 CPX30HL/LPG 5.0 2.7

CPx45 CPX45HL/LPG 10.2 3.9

CPx60 CPX60HL/LPG 8.2 3.5

CPx90 CPX90HL/LPG 5.5 2.6

CPx120 CPX120HL/LPG 7.6 3.5

CPx150 CPX150HL/LPG 10.6 4.4

CP x175 CPX175HL/LPG tbc tbc

CPx200 CPX200HL/LPG 6.9 3.9

CPx250 CPX250HL/LPG 10.0 4.7

CPx300 CPX300HL/LPG tbc tbc

Conversion Kit part number

mbar mbar

Propane (LPG) to Natural Gas Conversion Data

Nominal Inlet Pressure = 20mbar, Minimum Inlet Pressure = 17.5mbar Burner Pressure

High Fire Low Fire

MODEL

CPx30 CPX30HL/NG 3.4 1.5

CPx45 CPX45HL/NG 6.4 2.5

CPx60 CPX60HL/NG 5.8 2.5

CPx90 CPX90HL/NG 4.2 1.9

CPx120 CPX120HL/NG 6.0 2.6

CPx150 CPX150HL/NG 9 .1 3.3

CP x175 CPX175HL/NG 8.3 3.5

CPx200 CPX200HL/NG 6.9 4 .1

CPx250 CPX250HL/NG 9.3 5.8

CPx300 CPX300HL/NG tbc tbc

Conversion Kit part number

mbar mbar

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 63 of 68

Page 64

Appendices

Model 30 45 60 90 120

Rated Heat Capacity

Low Heat Input

Minimum Heat Capacity

Useful Efficiency

Electrical Power Consumption

Information required for ecodesign (ErP) Directive 2009/125

kW 30.0 43.2 60.0 90.0 120.0

Nett CV kW 20.0 27.0 40.9 64.5 81.4

kW 19.3 26.1 39.4 61.9 77.3

High Fire % 92% 91% 92% 92% 94%

Low Fire % 96% 97% 96% 96% 95%

High Fire kW 0.99 1.31 1.17 2.30 4.43

Low Fire kW 0.99 1.31 1.17 2.30 4.43

Standby kW <0.01 <0.01 <0.01 <0.01 <0.01

Ignition kW

NOx Seasonal (Gross)

Envelope Loss Factor

Emission Efficiency

Seasonal Space Heating Energy Efficiency

mg/kWh

% hs, flow

% hs,h

0.00 2.00 4.00 6.00 8.00

56.0 58.5 59.0 65.5 67.5

n/a n/a n/a n/a n/a

90% 91% 89% 92% 90%

73.6% 74.7% 72.5% 74.2% 72.8%

Model cont. 150 175 200 250 300

Rated Heat Capacity

Low Heat Input

Nett CV kW 94.8 122.0 152.8 183.3 tbc

Minimum Heat Capacity

Useful Efficiency

High Fire % 92% 92% 92% 93% tbc

Low Fire % 96% 95% 95% 96% tbc

High Fire kW 3.74 4.57 5.47 5.47 tbc

Low Fire kW 3.74 4.57 5.47 5.47 tbc

Electrical Power Consumption

Standby kW <0.01 <0.01 <0.01 <0.01 tbc

Ignition kW

NOx Seasonal (Gross)

Envelope Loss Factor

Emission Efficiency

Seasonal Space Heating Energy Efficiency

Seasonal Efficiency figure based on table 16 of the "Non-Domestic Building Services Compliance Guide". Extra efficiency credits are available

for High/Low burners and controlling via the Powrmatic MC200. 2 Excluding Distribution Fan

kW 150.0 175.0 200.0 250.0 tbc

kW 91.1 116.5 145.5 175.9 tbc

10.0 12.0 14.0 16.0 tbc

mg/kWh

69.2 65.5 84.9 97.3 tbc

% n/a n/a n/a n/a tbc

% hs, flow

% hs,h

91% 90% 89% 89% tbc

75.2% 72.9% 72.1% 72.5% tbc

page no. 64 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 65

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

Appendices

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 45 0.027 CPx 60 0.035 CPx 90 0.050 CPx 120 0.080 CPx 150 0.125 CPx 175 0.140 CPx 200 0.145 CPx 250 0.160 CPx 300 0.200

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 65 of 68

Page 66

Notes:

page no. 66 of 68

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

Page 67

Notes:

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

page no. 67 of 68

Page 68

www.powrmatic.co.uk

Getting In Touch

Powrmatic Limited Hort Bridge, Ilminster Somerset

Stamm International HQ

TA19 9PS tel: +44 (0) 1460 53535

Stamm International Corporation

fax: +44 (0) 1460 52341

PO Box 1929

e-mail: info@powrmatic.co.uk

Fort Lee, NJ 07024

web: www.powrmatic.co.uk

Tel: 201-947-1700 Fax: 201-947-9662 E-mail: stamminc@pobox.com

More information is available from our website by scanning the following QR code.

Powrmatic Ireland

45 Broomhill Close

Tallaght

Dublin 24

tel: +353 (0) 1452 1533

fax: +353 (0) 1452 1764

e-mail: info@powrmatic.ie

web: www.powrmatic.ie

Powrmatic pursues a policy of continues improvement in both design and performance of its products and therefore reserves the right to change, amend or

vary specifications without notice. Whilst the details contained herein are believed to be correct they do not form the basis of any contract and interested

parties should contact the Company to confirm whether any material alterations have been made since publication of this brochure.

page no. 68 of 68

ICOM

Energy Association

CPx Range Users, Installation & Servicing Instructions Doc Ref M201 issue 2.9 Nov 2018.

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Powrmatic CPx Series, CPx 30, CPx 120, CPx 150, CPx 175 User, Installation & Servicing Manual

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Frequently Asked Questions

User Manual