Powrmatic PTUL 35, PTUL 45, PTUL 30, PTUL 40, PTSL 25 Installation And Operation Instructions Manual

INSTALLATION AND OPERATION INSTRUCTIONS

OVERHEAD RADIANT TUBE HEATERS

Models: PTUL 25, PTUL 30, PTUL 35, PTUL 40, PTUL 45,

PTSL 25, PTSL 30, PTSL 35, PTSL 40, PTS L45

Single Stage Pull Through System (Negative Pressure)

0086

OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and understood before
installing, operating or servicing this heater. This heater is intended for use with either Natural Gas or Propane
Gas. It must be installed by a qualified service person or a licensed contractor in accordance with state and local
codes.

▲WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property damage,
injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or
servicing this equipment. For assistance or additional information, consult a qualified installer, service agency or
the gas supplier.

INSPECT all combustion air openings into the building and, if necessary, clear if they become blocked by dust.

FOR YOUR SAFETY: If the heater is installed without a flue, exhaust fans MUST be operating on an appropriate
cycle when heaters are operating to avoid a high concentration of carbon monoxide. When used without fresh
air, this heater may give off carbon monoxide, an odorless and poisonous gas. CARBON MONOXIDE POISONING
MAY LEAD TO DEATH. Early signs of carbon monoxide poisoning resemble the flue with headaches, dizziness and
nausea. If you experience these signs, GET FRESH AIR IMMEDIATELY! Have the heaters serviced as soon as
possible and check the ventilation in the house.

These heaters are designed for agricultural applications and may operate with the use of either Natural Gas or
Liquid Propane (LP) Gas. Check the heater’s nameplate to determine the correct gas type before proceeding
with installation.

!INSTALLER: This manual is the property of the owner. Please present this manual to the owner when you leave
the job site.

IF YOU SMELL GAS: FOR YOUR SAFETY

! DO NOT try to light any appliance.
! DO NOT touch any electrical switch; DO NOT use any

telephone in your building.

! IMMEDIATELY call your gas supplier from a neighbor's

telephone. Follow the gas supplier's instructions. If you
cannot reach your gas supplier, call the fire department.

!IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE.

Tel: [phone], Fax: [phone] www.powrmatic.co.uk

DO NOT store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.

Hort Bridge, Ilminster, TA19 9PS

Powrmatic Ltd

Form #44201150

Sept 2010

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0) Safety ................................................................................................................................................... 2

2.0) Installer Responsibility......................................................................................................................2

3.0) General Information ..........................................................................................................................2

4.0) Minimum Clearances to Combustibles........................................................................................... 4

5.0) Specifications ..................................................................................................................................... 5

6.0) Packing List......................................................................................................................................... 7

7.0) Dimensions – U Tube Configurations............................................................................................11

7.1) Heater assembly overview – u tube configurations ...................................................................13

8.0) Dimensions – LINEAR Tube Configurations.................................................................................16

8.1) Heater Assembly Overview - LINEAR tube configurations .........................................................17

9.0) Typical Suspension Methods..........................................................................................................20

9.1) Burner box support details..............................................................................................................21

9.2) User Instruction Label......................................................................................................................

10.0)

Typical heater assembly .................................................................................................................22

10.1) Tube coupling details.......................................................................................................................23

10.2)

Inserting Turbulators........................................................................................................................25

10.3) Attaching u-bend.............................................................................................................................25

10.4) Attaching burner Box Assembly.....................................................................................................26

10.5) Attaching Fan Assembly .................................................................................................................27

11.0) Gas Connections and Regulations ................................................................................................27

12.0) Instructions for Pressure Test Gauge Connection.......................................................................29

13.0) Electrical Connections.....................................................................................................................31

14.0) Venting and Fresh Air for Combustion..........................................................................................33

15.0) Lighting and Shutdown Instructions..............................................................................................38

16.0) Commissioning.................................................................................................................................39

17.0) Cleaning and Annual Maintenance ...............................................................................................39

18.0) Troubleshooting Guide ....................................................................................................................41

19.0) Replacing Parts ................................................................................................................................43

19.1) Removal of Electrodes ....................................................................................................................43

19.2) Removing Main Burner....................................................................................................................44

19.3) Removing Injector............................................................................................................................44

19.4) Removing Ignition Control ..............................................................................................................45

19.5) Removing Air Switch........................................................................................................................45

19.6) Removing Gas Valve and Manifold Assembly .............................................................................46

19.7) Removing Neon Indicator ...............................................................................................................46

19.8) Removing Air Inlet Plate .................................................................................................................47

19.9) Removing the Fan............................................................................................................................47

20.0) Conversion Instructions...................................................................................................................48

21.0) Installation Data...............................................................................................................................48

22.0) Replacement Parts Guide...............................................................................................................49

21

Form #44201150
Sept 2010 -1-

1.0) SAFETY

y

This heater is a self-contained infrared radiant tube heater. Safety information required during installation and
operation of this heater is provided in this manual and the labels on the product. The installation, service and
maintenance of this heater must be performed by a contractor qualified in the installation and service of gas
fired heating equipment.

All personnel in contact with the heater must read and understand all safety information, instructions and labels
before operation. The following symbols will be used in this manual to indicate important safety information.

Warning instructions must be followed to prevent or avoid hazards which
may cause serious injury, property damage or death.

Caution instructions must be followed to prevent incorrect operation or
installation of the heater which may cause minor injury or propert
damage.

2.0) INSTALLER RESPONSIBILITY

The installer is responsible for the following:

• The heater and venting, as well as electrical and gas supplies must be installed in accordance with these

installation instructions and any applicable codes and regulations.

• Every heater shall be located with respect to building construction and other equipment so as to permit

access to the heater.

• Each installer must follow the clearances to combustible materials for the heaters.

• Install the heater so that the supports and hangers are correctly spaced in accordance with these

instructions. The heater must be supported by materials having a working load limit of at least 52kg.

• Supply the owner with a copy of these Installation and Operation Instructions.

• Never use the heater as a support for a ladder or other access equipment. Do not hang anything from the

heater.

• Supply all installation materials necessary that are not included with the heater.

• Check the nameplate to make sure that the burner is correct for the gas type in the building.

3.0) GENERAL INFORMATION

This heater is a self-contained infrared radiant tube heater designed for use where flammable gases or vapors
are not generally present.

Installation of this heater must be in accordance with all applicable codes shown in the instructions and/or the
local codes and authorities having jurisdiction. In the UK all equipment must be installed and maintained in
accordance with the relevant provisions of the Gas Safety (Installations and Use) Regulations 1998 for gas fired
products. Installation practices must take into account the Health and Safety at Works Act 1974 or relevant
codes of practice. In addition the installation must be carried out in accordance with the current IEE wiring
regulations (BS 7671:2001), BS 6896:2005 (Industrial & Commercial) and any other relevant British Standards
and Codes of Practice by a qualified installer. All external wiring MUST comply with the current IEE wiring
regulations.

Clearances to combustibles as outlined in the manual should always be observed. In areas used for storage of
combustible materials where they may be stacked below the heater, the installer must post signs that will
“specify the maximum permissible stacking height to maintain the required clearances from the heater to
combustibles.”

Every heater shall be located with respect to building construction and other equipment so as to permit access
to the control housing. Each installer shall use skillful and reliable installation practices when locating the
heaters and must give consideration to service accessibility.

This heater is for INDOOR INSTALLATION ONLY and is used in VENTED or UNVENTED mode. The term Unvented
actually means Indirect Vented. While the products of combustion are expelled into the building, national codes
require ventilation in the building to dilute these products of combustion. This ventilation must be provided by
gravity or mechanical means. Ventilation requirements are addressed further in these instructions.

Although these heaters may be used in many applications other than space heating (e.g., process heating),
Powrmatic will not recognize the warranty for any use other than space heating.

-2- Sept 2010

Form #44201150

This heater is not an explosion proof heater. Where the possibility of exposure to volatile and low flash point
materials exists, it could result in property damage or death. This heater must not be installed in a spray booth
where the heater can operate during the spraying process. Consult your local fire marshal or insurance company.

Linear Configuration Series Only: Since linear configuration tube heaters are always hotter at the control end
than at the flue terminal end, always observe the minimum recommended mounting heights.

Fig. 1

HOT

WARM

WARM

Form #44201150
Sept 2010 -3-

4.0) MINIMUM CLEARANCES TO COMBUSTIBLES

Combustible material must be located outside the
clearance dimensions listed.

Failure to do so may result in death, serious injury or
property damage.

Minimum clearances to combustibles shall be measured from the outer surfaces as shown in the following
diagram:

END

END

ABOVE (CEILING) ABOVE (CEILING)

FRONT

SIDE

SIDE

REAR

BELOW

Fig. 2

Table 1

MINIMUM CLEARANCES TO COMBUSTIBLES

PTUL 25, PTS L25 510mm 450mm 1220mm 510mm 610mm 305mm
PTUL 30-45, PTSL 30-45 760mm 610mm 2285mm 610mm 760mm 380mm

▲WARNING: Certain materials or objects, when stored under the heater, will be subjected to radiant heat and
could be seriously damaged. Observe the Minimum Clearances to Combustibles listed in the manual and on the
heater at all times.

NOTE:

1. The clearances specified above must be maintained to combustibles and other materials that may be
damaged by temperatures 50ºC above ambient temperature. Clearances to combustibles are posted on the
control box. In areas used for storage of combustible materials where they may be stacked below the heater,
NFPA54 requires that the installer must post signs that will “specify the maximum permissible stacking height
to maintain the required clearances from the heater to combustibles.” Powrmatic recommends posting these
signs adjacent to the heater thermostat or other suitable location that will provide enhanced visibility.

2. The stated clearance to combustibles represents a surface temperature of 50 ºC above room temperature.
Building materials with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.) may be subject to
degradation at lower temperatures. It is the installer’s responsibility to assure that adjacent materials are
protected from degradation.

Side Above Below End Front Rear

BELOW

-4- Sept 2010

Form #44201150

5.0) SPECIFICATIONS

Table 2

MODEL PTUL 25/PTSL 25-N PTUL 25/PTSL 25-L
Heat Input 23.0 kW Hs 20.7 kW Hi

Appliance Type (II
Appliance Category
Adjusted for 2H G20 20mbar 3P G31 37mbar

Setting Pressure 12.5mbar 25mbar
Injector Ø3.8mm No. 39
Burner Baffle Plate PN 4260360C PN 4260360C
Fan Air Restrictor Plate None None
Electrical Supply 230V~50Hz 125W
Fuse Externally 3A
Dimensions PTUL 25: 5.385m x 0.465m PTSL 25: 10.065m x 0.34m
Weight PTUL 25: 47kg PTSL 25: 46kg
Gas Connection R - ½
Flue Size Ø100mm

Table 3

MODEL PTUL 30/PTSL 30-N PTUL 30/PTSL 30-L
Heat Input 29.2 kW Hs 26.3 kW Hi

Appliance Type (II
Appliance Category
Adjusted for 2H G20 20mbar 3P G31 37mbar
Setting Pressure 12.5mbar 25mbar
Injector No. 19 No. 34
Burner Baffle Plate PN 4260360D (9) PN 4260360D
Fan Air Restrictor Plate PN 42741170 PN 42741170
Electrical Supply 230V~50Hz 125W
Fuse Externally 3A
Dimensions PTUL 30: 5.51m x 0.715m PTSL 30: 9.955m x 0.34m
Weight PTUL 30: 66kg PTSL 30: 62kg
Gas Connection R - ½
Flue Size Ø100mm

Table 4

MODEL PTUL 35/PTSL 35-N PTUL 35/PTSL 35-L
Heat Input 34.5 kW Hs 31.1 kW Hi

Appliance Type (II
Appliance Category
Adjusted for 2H G20 20mbar 3P G31 37mbar
Setting Pressure 12.5mbar 25mbar
Injector No. 15 Ø3.1mm
Burner Baffle Plate PN 42760360E PN 42760360E
Fan Air Restrictor Plate PN 42741170 PN 42741170
Electrical Supply 230V~50Hz 125W
Fuse Externally 3A
Dimensions PTUL 35: 5.51m x 0.715m PTSL 35: 9.955m x 0.34m
Weight PTUL 35: 66kg PTSL 35: 62kg
Gas Connection R - ½
Flue Size Ø100mm

2H3P

2H3P

2H3P

)

)

)

, B

A

2

22, C12, C32, C52

A2, B

22, C12, C32, C52

A2, B

22, C12, C32, C52

II

2H3P

II

2H3P

II

2H3P

Form #44201150
Sept 2010 -5-

Table 5

MODEL PTUL 40/PTSL 40-N PTUL 40/PTSL 40-L
Heat Input 42.2kW Hs 38.0kW Hi

Appliance Type (II
Appliance Category

2H3P

)

A2, B

22, C12, C32, C52

II

2H3P

Adjusted for 2H G20 20mbar 3P G31 37mbar
Setting Pressure 12.5mbar 25mbar
Injector Ø 5.0mm Ø 3.3mm
Burner Baffle Plate PN 4260360S PN 4260360S
Fan Air Restrictor Plate None None
Electrical Supply 230V~50Hz 125W
Fuse Externally 3A
Dimensions PTUL40: 6.97m x 0.715m PTSL40: 13.00m x 0.34m
Weight PTUL 40: 81kg PTSL 40: 79kg
Gas Connection R - ½
Flue Size Ø100mm

Table 6

MODEL PTUL 45/PTSL 45-N PTUL 45/PTSL 45-L
Heat Input 47.0 Kw Hs 42.3 Kw Hi

Appliance Type (II
Appliance Category

2H3P

)

A2, B

22, C12, C32, C52

II

2H3P

Adjusted for 2H G20 20mbar 3P G31 37mbar
Setting Pressure 12.5mbar 25mbar
Injector Ø 5.4mm No. 28
Burner Baffle Plate PN 4260360H PN 4260360H
Fan Air Restrictor Plate None None
Electrical Supply 230V~50Hz 125W
Fuse Externally 3A
Dimensions PTUL 45: 6.97m x 0.715m PTSL 45: 13.00m x 0.34m
Weight PTUL 45: 81kg PTSL 45: 79kg
Gas Connection R - ½
Flue Size Ø100mm

-6- Sept 2010

Form #44201150

6.0) PACKING LIST

6.1 PTUL 25

The appliances are supplied as follows:­Table 7

REF PART NO. MODEL PTUL 25

1
2
3
4
5
6
8

9
10
11

44438010

4260021
4260372
4267923
4260020
4260375
4260384
4260383

44152248

Carton (containing the following)
Fastenings Pack
Burner Box Assembly
Fan Assembly – 3” (less air plate)
U-Bend
Hanger Bracket
Torctite Coupling
Radiant Tube (Ø 76.2 x 4572)
Reflector Panel (2438 long)
Reflector End Panel (notched)
Reflector End Panel (plain)
Turbulator (65mm x 572mm)

PTUL 25 Fig. 3

1
1
1
1
1
3
2
2
2
1
1
2

10

8

9

5

2

6

1

4

11

3

Form #44201150
Sept 2010 -7-

6.2 PTUL 30/35
PTUL 40/45

The appliances are supplied as follows:­Table 8

REF PART NO. MODEL PTUL 30 PTUL 35 PTUL 40 PTUL 45

1
2

2a

3
4
5
6
7
8

9
10
11

12

44438020
44438030

4260374
4260373
4267924
4250638
4250637
4260376
4260377
4260388
4260387

44152240

Carton (containing the following)
Fastenings Pack
Burner Box Assembly
Fan Assembly – 4” (with air plate)
Fan Assembly – 4” (less air plate)
U-Bend
Hanger Brackets
Torctite Coupling
Radiant Tube (Ø 101.6 x 3048)
Radiant Tube (Ø 101.6 x 1524)
Reflector Panel (2540 long)
Reflector Panel (1511 long)
Reflector End Panel (notched)
Reflector End Panel (plain)

Turbulator (90mm x 610mm)

1
1
1
1

­1
3
4
2
2
2

­1
1

8

1
1
1
1

­1
3
4
2
2
2

­1
1

5

1
1
1

­1
1
4
4
4

­2
1
1
1

1

PTUL 30/35 Fig. 4

11

1
1
1

­1
1
4
4
4

­2
1
1
1

-

8

10

7

2

5

1

6

4

12

3

PTUL 40/45 Fig. 5

8

9

8

10

6

2

6

5

1

5

4

11

3

12

-8- Sept 2010

Form #44201150

6.3 PTSL 25
The appliances are supplied as follows:­Table 9

REF PART NO. MODEL PTSL 25

1
2
3
4
5
7
8

9

44438010

4260245
4267923
4260020
4260176
4260244

44152248

Carton (containing the following)
Fastenings Pack
Burner Box Assembly
Fan Assembly – 3” (less air plate)
Hanger Brackets
Torctite Coupling
Radiant Tube (Ø 76.2 x 4 572)
Reflector Panel (3035 long)
Reflector End Panel

Turbulator (65mm x 572mm)

PTSL 25 Fig. 6

1
1
1
1
4
3
2
3
2

4

2

9

7

8

3

5

4

1

5

Form #44201150
Sept 2010 -9-

6.4 PTSL 30/35
PTSL 40/45

The appliances are supplied as follows:­Table 10

REF PART NO.

1
2

2a

3
4
5
6
7
8

44438020
44438030

4260245
4267924
4250638

44152240

4260174
4260244

Carton (containing the following)
Fastenings Pack
Burner Box Assembly
Fan Assembly – 4” (with air plate)
Fan Assembly – 4” (less air plate)
Hanger Brackets
Torctite Coupling
Radiant Tube (Ø 101.6 x 3048)
Turbulator (90mm x 610mm)
Reflector Panel (3035 long)
Reflector End Panel

MODEL

PTSL 30 PTSL 35 PTSL 40 PTSL 45

PTSL 30/35 Fig. 7

1
1
1
1

­4
4
3
9
3
2

1
1
1
1

­4
4
3
5
3
2

1
1
1

­1
5
5
4
3
4
2

6

1
1
1

­1
5
5
4

­4
2

2

7

8

3

5

4

1

PTSL 40/45 Fig. 8

2

6

7

8

3

5

4

1

-10- Sept 2010

Form #44201150

7.0) DIMENSIONS – U TUBE CONFIGURATIONS

1

Models:
PTUL 25

(from hanger to burner
suspension bracket)

691

243

527

152
(from end of tube
to hanger)

2250

Side View

76.2 (3) x 4572
Radiant Tube
(2 each)

50 (overlap)

4270

2020

Hanger Bracket
(3 each)

U-Bend

Burner
Box

Fig. 9

Models:
PTUL 30
PTUL 35

Fan
Assembly

Torctite
Coupling
(2 each)

(from hanger to burner
suspension bracket)

636

188

472

152
(from end of tube
to hanger)

Bottom View

75 (from end of
reflector to hanger)

Side View

2300

4270

End View

99

50 (overlap)

162

1970

Hanger Bracket
(3 each)

471

191

U-Bend

Burner
Box

Fan
Assembly

75 (from end of
reflector to hanger)

Fig. 10

Form #44201150
Sept 2010 -11-

Bottom View

101.6 (4) x 3048
Radiant Tube
(2 each)

Torctite
Coupling
(4 each)

End View

101.6 (4) x 1524
Radiant Tube
(2 each)

143

305

206

71

(from hanger to burner
suspension bracket)

Models:
PTUL 40
PTUL 45

Burner
Box

Fan
Assembly

636

188

472

152
(from end of tube
to hanger)

75 (from end of
reflector to hanger)

2350

Side View

3685

Bottom View

101.6 (4) x 3048
Radiant Tube
(4 each)

5855

Torctite
Coupling
(4 each)

1335
100 (overlap)

2170

85 (overlap)

143

206

U-Bend

305

Hanger Bracket
(4 each)

71

Fig. 11

End View

-12- Sept 2010

Form #44201150

7.1 HEATER ASSEMBLY OVERVIEW – U TUBE CONFIGURATIONS

U-Bend

U Type

Speed Clips

Turbulators

Reflector -

Foot End

Tube Support/

Hanger Bracket

(3 each)

Suspension

Chain

See Detail - B

Clamp in

open

position.

Clamp in

locked

position.

B

Clamp Detail -

A

(PTUL25)

Typical Assembly Overview

Reflector - 2438.4

(2 each)

U Type

See Detail - A

50

76.2 (3) Tube x 4572

(2 each)

4270

2250

U Bolt Clamp &

5/16 Hex Nuts

(typical)

Reflector Clamp

with Screw

(typical)

691

Torctite

Coupling

(2 each)

Speed Clips

Burner

Box

(reflector overlap)

See Detail - B

243

(from burner to reflector)

Clamp Detail -

319

(from burner to hanger)

Fig. 12

Form #44201150
Sept 2010 -13-

Reflector -

Control End

Fan

Assembly

Burner Box

Suspension

Chain

U Type

Speed Clips

Reflector -

Foot End

U-Bend

Turbulators

Suspension

Chain

See Detail - B

Clamp in

open

position.

Reflector - 2540

(2 each)

101.6 (4) Tube x 1524

(2 each)

Tube Support/

Hanger Bracket

(3 each)

101.6 (4) Tube x 3048

(2 each)

U bolt Clamp &

5/16 Hex Nuts

(typical)

4270

Reflector Clamp

with Screw

(typical)

Torctite

Coupling

(4 each)

2300

50

(reflector overlap)

See Detail - B

Clamp in

locked

position.

188

(from burner to reflector)

See Detail - B

264

Clamp Detail - B

Clamp Detail - A

(from burner to hanger)

(PTUL30 & PTUL35)

Typical Assembly Overview

Fig. 13

U Type

Speed Clips

Reflector -

Control End

636

Burner Box

Burner Box

Suspension

Fan Assembly

-14- Sept 2010

Chain

Form #44201150

U Type

Speed Clips

Reflector -

Foot End

U-Bend

Turbulators

See Detail - B

Clamp in

open

position.

Clamp Detail - B

U Type Speed Clips

(this joint only)

Reflector - 1511

Reflector - 2540

(2 each)

(PTUL40 & PTUL45)

Tube Support/

Hanger Bracket

(4 each)

2170

101.6 (4) Tube x 3048

(4 each)

U bolt Clamp &

5/16 Hex Nuts

(typical)

Reflector Clamp

Torctite

Suspension

Chain

with Screw

(typical)

Coupling

(4 each)

3685

2350

85

(reflector overlap)

See Detail - B

100

(reflector overlap)

See Detail - A

Clamp in

locked

position.

188

(from burner to reflector)

See Detail - B

Clamp Detail - A

264

(from burner to hanger)

Typical Assembly Overview

Fig. 14

Form #44201150
Sept 2010 -15-

U Type

Speed Clips

Reflector -

Control End

Fan Assembly

Burner Box

636

Burner Box

Suspension

Chain