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

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Page 1

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: +44 (0) 1460 53535, Fax: +44 (0) 1460 52341 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

Page 2

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

Form #44201150 Sept 2010 -1-

Page 3

1.0) SAFETY

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

Page 4

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

Form #44201150 Sept 2010 -3-

Page 5

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

ABOVE (CEILING) ABOVE (CEILING)

FRONT

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

Page 6

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

)

, B

22, C12, C32, C52

A2, B

22, C12, C32, C52

A2, B

22, C12, C32, C52

2H3P

Form #44201150 Sept 2010 -5-

Page 7

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

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

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

Page 8

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

Form #44201150 Sept 2010 -7-

Page 9

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

3 4 5 6 7 8

9 10 11

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

1 1 1 1

1 3 4 2 2 2

1 1

1 1 1

1 1 4 4 4

2 1 1 1

PTUL 30/35 Fig. 4

1 1 1

1 1 4 4 4

2 1 1 1

PTUL 40/45 Fig. 5

-8- Sept 2010

Form #44201150

Page 10

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

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

Form #44201150 Sept 2010 -9-

Page 11

6.4 PTSL 30/35 PTSL 40/45

The appliances are supplied as follows:Table 10

REF PART NO.

1 2

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

1 1 1

1 5 5 4

4 2

PTSL 40/45 Fig. 8

-10- Sept 2010

Form #44201150

Page 12

7.0) DIMENSIONS – U TUBE CONFIGURATIONS

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

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

Page 13

(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)

Fig. 11

End View

-12- Sept 2010

Form #44201150

Page 14

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.

Clamp Detail -

(PTUL25)

Typical Assembly Overview

Reflector - 2438.4

(2 each)

U Type

See Detail - A

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

Page 15

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

(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

Suspension

Fan Assembly

-14- Sept 2010

Chain

Form #44201150

Page 16

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

(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

Page 17

8.0) DIMENSIONS – LINEAR TUBE CONFIGURATIONS

Fan

Assembly

118

180

Hanger Bracket

(4 each)

2850

3065

End View - Burner

Fan

Assembly

Torctite

Coupling

50 (overlap)

76.2 (3) x 4572

Radiant Tube

Hanger Bracket

(4 each)

2850

Torctite

Coupling

3065

End View - Fan

Fan

Torctite

50 (overlap)

Assembly

Coupling

101.6 (4) x 3048

Radiant Tube

101.6 (4) x 3048

Radiant Tube

Hanger Bracket

(5 each)

2960

Torctite

Coupling

3086

Torctite

Coupling

2886

Torctite

Coupling

101.6 (4) x 3048

Radiant Tube

50 (overlap)

101.6 (4) x 3048

Radiant Tube

50 (overlap)

101.6 (4) x 3048

Radiant Tube

Torctite

Coupling

2930

691

152

(from hanger to burner

suspension bracket)

Models:

Fig. 15

50 (overlap)

Torctite

Burner

PTSL 25

76.2 (3) x 4572

Radiant Tube

Coupling

243

to reflector)

(from burner

Box

50 (overlap)

Torctite

Coupling

2930

636

152

suspension bracket)

(from hanger to burner

Models:

PTSL 30

PTSL 35

101.6 (4) x 3048

Radiant Tube

Torctite

Coupling

188

(from burner

Burner

Box

Torctite

Coupling

636

to reflector)

suspension bracket)

(from hanger to burner

2960

152

Models:

PTSL 40

PTSL 45

50 (overlap)

101.6 (4) x 3048

Radiant Tube

Torctite

Coupling

Burner

Box

188

to reflector)

(from burner

-16- Sept 2010

Form #44201150

Page 18

8.1) HEATER ASSEMBLY OVERVIEW - LINEAR TUBE CONFIGURATIONS

Fan Assembly

Turbulators

U Type

Speed Clip

(this joint only)

76.2 (3) Tube x 4572

Tube Support/

Suspension

Chain

Hanger Bracket

2850

(4 each)

#10 Self-Drill Screws

(Typical all tube couplings.)

U-Bolt Clamp &

5/16" Hex Nuts

(typical)

3065

See Detail - B

(reflector overlap - typical)

See Detail - A

Clamp in

open

position.

Clamp in

locked

position.

Clamp Detail - B

Clamp Detail - A

(PTSL25)

Reflector - 3035

(3 each)

Typical Assembly Overview

Fig. 16

Form #44201150 Sept 2010 -17-

U Type

Speed Clip

Reflector -

End Panel

(2 each)

76.2 (3) Tube x 4572

Reflector Clamp

with Screw

Torctite

2930

(typical)

Coupling

(3 each)

Burner Box

691

See Detail - B

Burner Box

Suspension

Chain

243

(from burner to reflector)

319

(from burner to hanger)

Page 19

Fan

Assembly

Turbulator

U Type

Speed Clip

(this joint only)

3 each

101.6 (4) Tube x 3048

Tube Support/

Hanger Bracket

(4 each)

U-Bolt Clamp &

5/16" Hex Nuts

(typical)

Suspension

Chain

2850

3065

#10 Self-Drill Screws

(Typical all tube couplings.)

See Detail - B

(reflector overlap - typical)

See Detail - A

Clamp in

open

position.

Clamp in

locked

position.

Clamp Detail - B

Clamp Detail - A

Reflector - 3035

(3 each)

(PTSL30 & PTSL35)

Typical Assembly Overview

Fig. 17

Reflector -

End Panel

(2 each)

U Type

Speed Clip

Reflector Clamp

with Screw

(typical)

Torctite

Coupling

(4 each)

Burner Box

-18- Sept 2010

2930

636

See Detail - B

Burner Box

Suspension

Chain

188

(from burner to reflector)

264

(from burner to hanger)

Form #44201150

Page 20

Fan

Assembly

Turbulators

Suspension

101.6 (4) Tube x 3048

4 each

Chain

2960

See Detail - B

Clamp in

open

position.

See Detail - A

Clamp Detail - B

Fig. 17a

Reflector - 3035

(4 each)

(PTSL40 & PTSL45)

Typical Assembly Overview

Reflector -

#10 Self-Drill Screws

(Typical all tube couplings.)

U-Bolt Clamp &

5/16" Hex Nuts

End Panel

(2 each)

(typical)

Reflector Clamp

with Screw

U Type

Speed Clip

3086

(typical)

Tube Support/

2886

Hanger Bracket

(5 each)

Torctite

Coupling

(5 each)

Burner Box

2960

636

See Detail - B

(reflector overlap - typical)

See Detail - A

See Detail - B

Burner Box

Suspension

Chain

Clamp in

locked

position.

Clamp Detail - A

188

(from burner to reflector)

264

(from burner to hanger)

Form #44201150 Sept 2010 -19-

Page 21

9.0) TYPICAL SUSPENSION METHODS

Not withstanding their limited scope, the appliance should be installed in accordance with the relevant provisions of any National Gas Safety (Installation and Use) Regulations. Due account should also be taken of any obligations arising from any National Heath and Safety at Work Regulations, National and Local Building Regulations and National Electrical Wiring Regulations. The appliance must be installed, and where necessary, converted for use on other gases, by a qualified installer.

Burner must be secured to the mounting flange with nuts.

SUSPENSION HAZARD

All materials used to suspend the heater must have a minimum working load of 52kg. All S Hooks must be crimped closed.

Never use the heater to support a ladder or other access equipment. Failure to do so may result in death, serious injury or property damage.

Various means of suspending the heater can be used. See the following drawings for typical examples.

a. Use only noncombustible materials for suspending hangers and brackets. b. Linear Tube Heaters should be suspended to provide a slope of 0.25 degree up to the fan (25 to 50mm). The

appliance should be located with respect to building construction and other equipment to permit access to the appliance for servicing etc.

c. U-Tube Heaters should be suspended horizontally along the length. d. Turnbuckles can be used with chains to allow leveling of the heater. All “S” hooks and eye bolts must be

manually crimped closed by the installer.

e. For suspending the appliance it is recommended that suitable protected welded chain (Ø 3mm x 65 links

per m) or Ø 8mm min mild steel drop rods and suitable brackets are used. Attach the chains or drop rods to the hanger brackets where shown providing at least Ø5mm closed link hooks are used chains may be attached directly to the hanger brackets.

f. Heaters subject to vibration must be provided with vibration isolating hangers. g. Heaters must not be supported by gas or electric supply lines and must be suspended from a permanent

structure with adequate load capacity.

h. Hanging points are fixed along the length of heater to accommodate trim pieces. Secondary steel work may

be required to span between supporting beams.

i. The appliance should be located with respect to building construction and other equipment to permit access

to the appliance for servicing etc.

Powrmatic recommends that the body sections be suspended using chains with turnbuckles. This will allow slight adjustments after assembly and heater expansion/ contraction during operation.

If a “trapeze” method is used for tube support/hanger brackets (shown below), the minimum chain length for the two connecting chains is 914 mm to minimize any vibration that might be generated by the draft inducer assembly. If these chains must be less than 914 mm, then do not use the trapeze method and, instead, use individual chains on each tube support/hanger bracket.

IMPORTANT: When U-Tube Heaters are angle mounted (see Fig 18) the fan should be assembled to the higher of the two emitter tubes as shown.

-20- Sept 2010

Form #44201150

Page 22

PTUL09, PTUL12, PTUL15, PTUL25

PTUL30, PTUL35, PTUL40, PTUL45

PTSL09, PTSL12, PTSL15, PTSL25, PTSL30, PTSL35, PTSL40, PTSL45

Fig. 18

Latch

Neon Lights

Horizontal Mounting

Latch

30°

Neon Lights

Angle Mounting

( 30° MAX.)

Latch

Neon Lights

Horizontal Mounting

Latch

30°

Neon Lights

Angle Mounting ( 30° MAX.)

Latch

Neon Lights

Horizontal Mounting

Latch

30°

Neon Lights

Angle Mounting ( 30° MAX.)

Latch

Neon Lights

Horizontal Mounting (with alternate trapeze hanging method)

9.1) BURNER BOX SUPPORT DETAILS

1. The burner box must be supported with a welded chain after overall heater suspe nsion is complete. This is to prevent burner from sagging which may cause th e tube to burn tube out prematurel y. Assemble bracket and turnbuckle to inlet end of burner as shown.

Fig. 19

Welded Chain

Turnbuckle

Adjust turnbuckle

Bracket

M6 Nut & Washer

to level control.

Level

Lights must face down.

2. Adjust the turnbuckle until control box is level. Use a leveling device to verify.

Failure to install the burner box suspension chain vertically will void the manufacturers warranty.

Linear heaters must be angled up from the burner box. Failure to do so may result in overheating of internal components resulting in equipment failure.

1/4 Deg.

Angle up to fan 50mm over the length of the heater. (linear heaters)

Form #44201150 Sept 2010 -21-

Page 23

9.2) USER INSTRUCTION LABEL

The User Instruction label shown below is supplied with each heater. Affix this label adjacent to low level user controls, such as thermostats, time clocks or control panels.

OVERHEAD RADIANT HEATER OPERATING INSTRUCTIONS

1. TURN ON GAS SUPPLY.

2. SET TIME SWITCHES OR THERMOSTATS TO DEMAND HEAT.

3. SWITCH ON ELECTRICITY SUPPLY. RED & AMBER NEON INDICATOR ON.

4. BURNER SHOULD IGNITE WITHIN 15 SECONDS, AMBER NEON INDICATOR ON.

5. IF IGNITION IS NOT ACHIEVED DURING 12 SECOND IGNITION PERIOD LOCOUT OCCURS. THIS IS INDICATED BY THE AMBER NEON OFF. INTERUPT ELECTRICITY SUPPLY TO APPLIANCE FOR 10 SECONDS TO RESET IGNITION CONTROL. IF A FIRST RESET IS NOT SUCCESSFUL, WAIT AT LEAST 15 SECONDS BEFORE REPEATING PROCEDURE. AFTER RESET, AN EXTENDED WAITING TIME WILL OCCUR.

6. IF FLAME IS LOST DURING NORMAL RUNNING, THE AUTOMATIC IGNITION CONTROL WILL REPEAT START PROCEDURE AS AT 4 ABOVE.

7. IF THE APPLIANCE FAILS TO IGNITE AFTER SECOND START SEQUENCE, SWITCH OFF ELECTRICITY SUPPLY TO APPLIANCE AND CALL SERVICE ENGINEER.

8. TO SHUT DOWN APPLIANCE, TURN OFF GAS AND ELECTRICITY SUPPLIES.

AFFIX THIS LABEL ADJACENT TO LOW LEVEL USER CONTROL.

4260440

Fig. 20

10.0) TYPICAL HEATER ASSEMBLY

CUT HAZARD

Sheet metal parts, particularly reflectors and vent have sharp edges. Always use gloves when handling.

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

See heater dimensions and assembly overview (Sections 7.0 through 8.1) for each U-model and Linear model configurations.

During field assembly of the heater body sections, the recommended procedure is as follows:

1. Determine the actual layout of the system first before hanging heater sections. Consideration must also be

taken for flue pipe, fresh air ducting, gas piping, clearances to combustibles, etc. before hanging heater.

2. Install the heater suspension using chains or other type methods outlined in Section 9 “Typical Suspension

Methods”. Space these per the assembly overview for each heater.

3. Space two (2) tube support/hanger brackets at distances indicated in each assembly overview for the first

tube section. Note: The distances are measured from center of the slotted holes of each support/hanger bracket.

4. Place tubes over these brackets with the welded seam facing down toward the ground. Failure to assemble

the tube with the seam facing down will void the manufacturer’s warranty. Secure the tubes to each support/hanger bracket using U-bolt clamps and 5/16-18 nuts provided.

5. Raise the tube section up to the suspension chain (or other methods), using “S” hooks to attach the tube

support brackets. Hang each tube section individually. DO NOT assemble all of the heater tube sections together on the ground and attempt to hang the entire system. Provide a slope of 0.25 degree up to the fan on linear tube heaters.

6. Continue to pre-assemble and hang each additional section as before. Join each section together using

Torctite couplings as described in Section 10.1 “Tube Coupling Details”.

7. Insert turbulators (where required) into the tube sections as shown in Section 10.2 “Inserting Turbulators”.

8. Place U-bend (U-model heaters only) as shown in Section 10.3 “Attaching U-Bend”.

9. Place main body reflector panels over each of the tube support/hanger brackets installed above.

10. Attach burner box and fan assembly as shown in Sections 10.4 and 10.5 respectively.

-22- Sept 2010

Form #44201150

Page 24

11. Slide reflector panels and space between burner box and U-bend (U-model heaters only) as indicated on

heater dimension drawings. Reflectors must overlap approximately as shown on the dimension drawings.

12. Secure reflectors to tube support/hanger brackets using the screws and clamps (supplied in fastening kits).

Note: Refer to details A or B of each assembly overview drawing for the required open or closed positions of the clamps. These positions enable reflectors to side or remain stationary during operation of heater.

13. Place end reflector panels flush to each end of main heater reflector panels and secure by spacing two (2) U-

type speed clips (supplied in fastening kits) evenly on edges of each reflector flange.

14. Make all final gas and electric connections as outlined later in the instructions.

15. Affix user instruction label adjacent to controls. See section 9.2.

Failure to assemble the tube with the seam facing down will void the manufacturer’s warranty.

10.1) TUBE COUPLING DETAILS

Join the tube sections together and secure with tube couplings as described below. Note: The heater tube section should be provided a slope of 0.25 degree up to the fan.

The following coupling tightening instructions MUST be followed properly to ensure the integrity of the tube connections. Two #10 self-drilling screws MUST be installed at every coupling as shown in the instructions below. Failure to do so may result in serious injury or property damage.

a. Place the compression coupling over the end of the tube. b. Use the small hole at the centerline of the coupling to check that the coupling is inserted correctly. c. Partially tighten the bolt nearest the end of the tube (approximately half closed).

Tube

Center end of Tube with hole

Tube Coupling

Partially tighten this bolt

Fig. 21

d. Slide the next tube into the coupling. e. Make sure both tube ends are butted together. f. Finish tightening both bolts to 54-80 N·m torque to ensure a complete seal. g. Use the two self-drilling screws through the pre-punched holes to secure the tubes in the coupling.

Center both tubes with hole

Tube Coupling

#10 Self-Drilling Screws (QTY 2)

Fig. 22

h. Check to ensure that the hardware is completely closed and the band is seated on the reaction block and

interference pins as illustrated above.

Form #44201150 Sept 2010 -23-

Page 25

i. Once all the heater body sections are attached, make sure that the heater system is level. If it is not, slight

adjustments can be made using the turnbuckles. (See Section 7.0) Fig. 23

Band

Force Bars

Reaction Block

Bolt

Interference Pins

CORRECT INSTALLATION

INCORRECT INSTALLATION

Important: NEVER reuse a coupling. Always install a new coupling only and torque as per instructions above and the diagrams above.

10.2) INSERTING TURBULATORS

POISONOUS GAS AND SOOT HAZARD

The heater must be assembled with the correct number of turbulator sections and tube length for the rated heat input.

The turbulators must be installed in the tube sections as shown below.

Failure to do so may result in death, serious injury, property damage or illness from Carbon Monoxide poisoning.

1. Assemble the turbulators together by interlocking the slotted end portions.

2. Slide these into the last tube sections located at the U-bend as shown for U-Models or into the last tube

section located at the fan as shown for Linear Model heaters.

3. Align turbulator end flush with end of tube.

Note: Refer to the table below for quantities of turbulators required for each heater model.

Turbulators on Burner Leg

U-MODEL HEATERS

Bottom View

LINEAR MODEL HEATERS

Bottom View

at U-Bend End

Turbulators on Fan Leg at U-Bend End

Turbulators at Fan End

End View

Radiant Tube

a. 76.2mm b. 101.6mm

Turbulators (insert in flat position)

a. 65mm wide x 572mm long b. 90mm wide x 610mm long

Fig. 24

-24- Sept 2010

Form #44201150

Page 26

Table 11

U-Model

Heaters

Linear Model

Heaters

MODEL Turbulator Sections Burner Leg Fan Leg Fan End

PTSL 25 65mm x 572mm - - 4 PTUL 25 65mm x 572mm 2 - PTSL 30 90mm x 610mm - - 9 PTUL 30 PTSL 35 PTUL 35 PTSL 40

90mm x 610mm 90mm x 610mm 90mm x 610mm 90mm x 610mm

3 5 -

- - 5

3 2 -

- - 3

PTUL 40 90mm x 610mm 1 - - PTSL 45 90mm x 610mm - - - PTUL 45 90mm x 610mm - - -

10.3) ATTACHING U-BEND

U-Bend (76.2mm Tubes)

1. Assemble the U-Bend to the tubes with the two (2) threaded holes facing downwards, ensuring that the tubes engage fully.

2. Using two (2) 5/16” BSW hexagon socket setscrews (from fastening pack) secure the U-Bend to the radiant tubes.

IMPORTANT: Failure to assemble the radiant tubes with their welded seam facing away from the reflector will void the manufactures warranty.

U-Bend (101.6mm Tubes)

1. Assemble the U-Bend to the tubes, ensuring that the tubes engage fully.

2. Drill one midway along the swaged portion of the U-Bend.

3. Rivet the U-Bend to the radiant tubes using the two

IMPORTANT: Failure to assemble the radiant tubes with their welded seam facing away from the reflector will void the manufactures warranty.

Ø 5.5mm hole through the U-Bend and radiant tube in the lower surface of each leg at a distance

Ø 5 x 10 rivets provided (from fastening pack).

PTUL 25 U-Bend Attachment (76.2mm tubes)

5/16 BSW Hexagon

Note: Welded seam of tube must be positioned on bottom side.

Socket Setscrews

Fig. 25

Form #44201150 Sept 2010 -25-

Bottom View

PTUL 30/35/40/45 U-Bend Attachment

Note: Welded seam of tube must be positioned on bottom side.

(101.6mm tubes)

Drill through - Ø 5.5mm. Secure using

Ø 5 x 10 rivets.

Bottom View

Page 27

10.4) ATTACHING BURNER BOX ASSEMBLY

END VIEW (mounting position)

Warning:

LIGHTS MUST FACE DOWN. Failure to do so will result in overheating the ignition module and will invalidate the warranty.

Radiant Tube (76.2mm)

Torctite Coupling

#10 Self-Drilling Screws (QTY 2)

Tube Connection (Ø 76.2mm) Models: PTSL25 and PTUL25

Radiant Tube (101.6mm)

Torctite Coupling

Tube Connection (Ø 101.6mm) Models:

PTSL40, PTSL45, PTUL30, PTUL35, PTUL40, PTUL45

PTSL30, PTSL35,

#10 Self-Drilling Screws (QTY 2)

Fig. 26

a. Place a Torctite Coupling over the end of the Radiant Tube (refer to Section 10.1 “Tube Coupling Details”).

Assemble the Burner Box to the Radiant Tube ensuring that it engages fully into the Torctite Coupling and is positioned vertically. Tighten the bolts of the Torctite Coupling to secure the Burner Box to the Radiant Tube, taking care to support the Burner Box in line with the axis of the tube.

NOTE: Tighten the Torctite Coupling bolts alternately while continually checking for slackness of the joint.

b. Assemble the end reflector flush with the end of the main body reflector. Secure by sliding speed clips

(supplied in fastening kit) onto the reflector edges. Evenly space the speed clips on the sides and top of the reflectors to provide a snug fit.

-26- Sept 2010

Form #44201150

Page 28

10.5) ATTACHING FAN ASSEMBLY

Torctite Coupling

Ø 101.6mm)

Radiant Tube (101.6mm)

#10 Self-Drilling Screws (QTY 2)

Tube Connection (Ø 76.2mm) Models: PTSL25 and PTUL25

Torctite Coupling

Radiant Tube (76.2mm)

#10 Self-Drilling Screws (QTY 2)

Tube Connection ( Models: PTSL30, PTSL35, PTSL40, PTSL45, PTUL30, PTUL35, PTUL40, PTUL45

Fig. 27

a. Place a Torctite Coupling over the end of the Radiant Tube (refer to Section 10.1 “Tube Coupling Details”).

Assemble the Fan Assembly to the Radiant Tube and position the fan outlet pointing upwards for flueless applications. Tighten the bolts of the Torctite Coupling to secure the Fan Assembly to the Radiant Tube, taking care to support the Fan Assembly in line with the axis of the tube.

NOTE: Tighten the Torctite Coupling bolts alternately while continually checking for slackness of the joint.

b. Assemble the end reflector flush with the end of the main body reflector. Secure by sliding speed clips

(supplied in fastening kit) onto the reflector edges. Evenly space the speed clips on the sides and top of the reflectors to provide a snug fit.

11.0) GAS CONNECTIONS AND REGULATIONS

Tighten flexible gas hose and components securely.

Flexible metal gas hoses must be installed without any twists or kinks in them. The hose will move during operation of the heater and it can crack if it is twisted.

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

IMPORTANT BEFORE CONNECTING THE GAS TO THE HEATER

a. Connect to the supply tank or manifold in accordance with state or local building codes. Authorities having

jurisdiction should be consulted before the installation is made.

b. Check that the gas fuel on the burner rating plate matches the fuel for the application. c. Check that the gas supply piping has the capacity for the total gas consumption of the heaters and any other

equipment connected to the line.

d. Check that the calculated supply pressure with all gas appliances and heaters operating will not drop below

the minimum supply pressure required for these heaters. See Table 11a Below.

Table 11a Gas type Appliance

Category

Nominal Supply Pressure

Maximum Supply Pressure

Minimum Supply Pressure

Setting Pressure

Natural Gas (G20) 2H 20 mbar 25 mbar 17 mbar 12.5 mbar LPG (G31) 3P 37 mbar 45 mbar 30 mbar 25 mbar

e. All gas supply lines must be located in accordance with the required clearances to combustibles from the

heater as listed on the clearances label of the heater and (Section 4.0) of this manual.

f. Pipe joint compounds must be resistant to the action of liquefied petroleum gases. g. Tube heaters will expand/contract during operation. Use an approved flexible connector for connections

between the rigid piping and the heater. A union should be installed before the control box inlet. An approved shut off valve should be installed within 1.8m of the union.

h. The gas pipe, flexible hose and connections must be self supporting. The gas pipe work must not bear any of

the weight of the heater or any other suspended assembly.

Form #44201150 Sept 2010 -27-

Page 29

i. This appliance is equipped with a step-opening, combination gas valve. The maximum supply pressure to the

appliance is 60 mbar. If the line pressure is more than the maximum supply pressure, then a second stage regulator which corresponds to the supply pressure must be used.

j. After all gas connections have been made, make sure the heater and all gas outlets are turned off before

the main gas supply is turned on slowly. Turn the gas supply pressure on and check for leaks.

k. If a 2nd stage regulator is used, the ball valve down stream in the supply line must be closed when purging

the gas lines to prevent gas seeping through it. If initial gas pressure is higher than 60 mbar the redundant combination gas valve is designed to lock out. Pressure build-up in the supply lines prior to the heater must be released before proper heater operation.

Do not use an open flame of any kind to test for leaks.

KEY DIMENSIONS AND COMPONENTS OF THE GAS CONNECTIONS

Fig. 28

Fig. 29

Alternate Supply Locations

Approved Flexible Connector

36 to 43cm

END VIEW

5cm Max. Displacement

Second Stage Regulator with Vent Leak Limiter to reduce the Supply Pressure below 60mbar if required

Adaptor R - 1/2 male

Control Box

Movement

SIDE VIEW

INCORRECT POSITIONS

Gas Supply Piping

Manual Gas Shut Off Valve

Sediment Trap (Drip Leg)

Adaptor R - 1/2 female

Movement

WRONG

Fig. 30

Radiant tube heaters will expand and contract during operation. Therefore it is essential to provide a flexible metallic hose, which must conform, to national or Local Regulations, to connect the appliance to the gas supply. Minimum size to be ½" (12.7mm) bore.

The gas pipe, flexible hose and connections must be self supporting. The gas pipe work must not bear any of the weight of the heater or any other suspended assembly.

Movement

WRONG

Movement

WRONG

-28- Sept 2010

Movement

WRONG

Form #44201150

Page 30

12.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION

CHECKING GAS PRESSURES

a. Switch off the electricity supply to the appliance. b. Connect a manometer to the test nipple protruding from the rear panel of the Control Box (adjacent to the

Air Inlet Adaptor). See Fig. 31. Open the Control Box door after releasing the two toggle latches.

Control End View

Test Nipple (manometer tube connection)

25 mbar

Digital or Water Column Manometer scale 0-100mbar

Manometer Tubing

Pressure Test Nipple LEFT (Gas In)

Pressure Govenor Adjuster

Control Front View (access panel not shown)

Pressure Test Nipple RIGHT (Gas Out)

Fig. 31 TO CHECK THE GAS SUPPLY PRESSURE

a. Unscrew the sealing screw (two turns) of the LEFT (Gas IN) Control Valve test nipple and connect the free end

of the manometer tube (permanently connected to the manometer test nipple inside the side panel of the control box) to this test nipple (See Fig. 31). Close the control box door and secure with the two toggle latches.

b. Ignite the appliance burner by switching on the electricity supply to the appliance and check that the

manometer reading is as stated below for the gas type the appliance is "adjusted for" (see the Data Label affixed to the Control Box door). See table 11a for gas supply.

c. Switch off the electricity supply to the appliance open the control box door and remove the manometer tube

from the LEFT (Gas IN) control valve test nipple. Screw in the test nipple sealing screw.

TO CHECK THE BURNER SETTING PRESSURE

a. Unscrew the sealing screw (two turns) of the RIGHT (Gas OUT) Control Valve test nipple and connect the free

end of the manometer tube (permanently connected to the manometer test nipple inside the side panel of the control box) to this test nipple (See Fig. 31). Close the control box door and secure with the two toggle latches.

b. Ignite the appliance burner by switching on the electricity supply to the appliance and check that the

manometer reading is as stated below for the gas type the appliance is adjusted for (see the Data Label affixed to the control box door).

Category 2H: gas type G20 (natural): setting pressure 12.5mbar

Category 3P: gas type G31 (propane): setting pressure 25mbar

c. In the event that the burner setting pressure is incorrect, switch off the electricity supply to the appliance

and remove the cap from the integral pressure governor for the Control Valve (see Fig. ). Close the control box door and switch on the electricity supply to the appliance to ignite the burner. Remove the plug from the control box door and insert a suitable screwdriver through the exposed hole in the box to locate the governor adjusting screw. Adjust the pressure by turning the pressure governor adjusting screw clockwise to increase or anti-clockwise to decrease the burner setting pressure. See Fig. 32.

Form #44201150 Sept 2010 -29-

Page 31

25 mbar

Remove hole plug.

Use screwdriver for pressure adjustment at govenor.

Fig. 32

d. Upon obtaining the correct burner setting pressure switch off the electricity supply to the appliance, remove

the screwdriver, replace the plug into the upper surface of the control box door and open the door. Remove the manometer tube from the RIGHT (Gas OUT) Control Valve test nipple and screw in the test nipple sealing screw. Close the control box door and secure with the two toggle latches.

FLAME SUPERVISION

a. To check the operation of the flame supervision equipment, run the appliance normally, turn off the gas

supply at the gas isolation valve and observe that the amber neon indicator remains illuminated.

b. After a purge period of 10 seconds (minimum) the solenoid valves and the ignition spark electrode will be re-

energized and with the gas still turned off, the ignition control will go to "lockout" condition after a further 12 seconds (maximum). Amber neon indicator extinguished.

c. Switch off the electricity supply to the appliance for a period of 10 seconds before attempting to re-ignite the

burner. (see Section 13.0).

-30- Sept 2010

Form #44201150

Page 32

13.0) ELECTRICAL CONNECTIONS

ELECTRIC SHOCK HAZARD

Disconnect electrical power and gas supply before servicing.

This appliance must be connected to earth.

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

a. The electrical wiring to this heater must be installed in accordance with the latest or current National

Regulations and any Local Regulations, which apply.

Electrical supply 230V~50Hz 125W

Current rating 0.55

Fuse externally 3A

b. Twin core and earth PVC covered flexible supply cable (0.5mm2-to National or Local standard specification)

must be used, with connection made as follows:

Single Heaters per Thermostat connection diagram

GREEN/YELLOW

BLUE

BROWN

Thermostat

Fig. 33

Multiple Heaters per Thermostat connection diagram

Service Switch

2 7

Heater 1

Thermostat

Service Switch

Continue To Additional Heaters

2 7

Heater 2

GREEN/YELLOW

BLUE

BROWN

Thermostat

Fig. 34

Notes: The method of connection to the electrical supply must facilitate complete isolation and should preferably be via a fused double pole isolator having a constant separation of at least 3mm in all poles and supplying the appliance ONLY.

Alternatively, connection may be made via a fused 3 pin plug and un-switched, shuttered socket, both complying with the requirements of National or Local Regulations. Neither thermostat nor switch are supplied as standard equipment. NOTE: In the event of an electrical fault after installation of the appliance, preliminary system checks are required to be carried out i.e. earth continuity, polarity and resistance to earth.

Form #44201150 Sept 2010 -31-

Service Switch

2 7

Heater 1

Service Switch

Continue To Additional Heaters

2 7

Heater 2

Page 33

c. Internal Wiring Diagram

TO FANPOWER IN

COM

AIR SWITCH

WIRING COLOUR CODES BL = BLUE

BR = BROWN GR = GREY G/Y = GREEN & YELLOW R = RED V = VIOLET W = WHITE Y = YELLOW

G/Y

R BR

G/Y BL

123456789101112

IGNITION MODULE CONNECTION

G/Y

AMBER NEON

R V

RED NEON

G/Y

3.5

ELECTRODE

Fig. 35

-32- Sept 2010

Form #44201150

Page 34

14.0) VENTING AND FRESH AIR FOR COMBUSTION

POISONOUS GAS AND SOOT HAZARD

Heaters installed unvented must be installed in an area with at least 10m

In buildings with airborne contamination such as poultry houses the heater must be installed with fresh air for combustion.

Failure to do so may result in death, serious injury, property damage or illness from Carbon Monoxide poisoning.

These appliances may be installed with an exhaust flue fitted or without an exhaust flue fitted.

A. FLUELESS (UNFLUED)

The installation room should have a volume of at least 10m³/kw of installed nominal heat input of the radiant heater.

The ventilation requirements and calculation methods for unflued appliances are set out in the European Standards EN 13410:2001 and must be applied. The following is guidance to the standard:

Ventilation may be achieved by any of the three following different means:

a) Thermal evacuation of the products of combustion/air mixture

b) Mechanical evacuation of the products of combustion/air mixture

c) Natural air change

VENTILATION BY THERMAL EVACUATION

a. Ventilation by thermal evacuation is sufficient if 10m³/h of exhaust air per kW of operating heat input are

ventilated out of the installation room.

b. The air/products of combustion mixture must be evacuated above the radiant heaters, if possible near the

ridge, by means of exhaust mixture opening(s), (vents).

c. Where the exhaust mixture opening(s) can be closed, it shall only possible to operate the radiant heaters

when they are open.

d. The maximum horizontal distance between a radiant heater and a vent opening shall be:

6 (six) times the vent height in the case of wall openings

3 (three) times the vent height in the case of roof openings

/ hr per kW heat input of outside air ventilation.

VENTILATION BY MECHANICAL EVACUATION a. Ventilation by mechanical evacuation is sufficient if 10m³/h of exhaust air per kW of operating heat input

are ventilated out of the installation room.

b. The air/products of combustion mixture must be evacuated above the radiant heaters using fan(s). c. It shall only be possible to operate the radiant heaters whilst the exhaust airflow is proven. d. The maximum horizontal distance between a radiant heater and a fan shall be:

6 (six) times the fan mounting height in the case of wall openings

3 (three) times the fan mounting height in the case of roof openings

e. Total minimum proven ventilation airflow in m³/h will be:

Total installed kW input X 10

Note: Mechanical exhaust air openings must be positioned such that the burner stability of the nearest appliance is unaffected.

Form #44201150 Sept 2010 -33-

Page 35

VENTILATION BY NATURAL AIR CHANGE Gas-fired radiant heaters may be operated without any special exhaust system if the exhaust gases are discharged to the outside atmosphere by a sufficient natural air change in the installation room.

Furthermore, no provision for thermal or mechanical ventilation is required in the following particular cases:

Buildings with natural air change greater than 1.5 volumes per hour Buildings with a density of operating heat input not greater than 5W/m³

AIR SUPPLY Air supply openings are required to admit air and shall be located below the radiant heaters.

The total area of the unobstructed cross-sections of all the air supply openings shall not be smaller than the total area of the unobstructed cross-sections of all the exhaust openings.

Slits and gaps of fixed cross-section can also be used as air supply openings.

Where the air supply openings can be closed, it shall only be possible to operate the radiant heaters when they are open.

B. FLUED

If the appliance is to be flued externally, then flue pipe of diameter stated in Table 12, and complying with National and Local Regulations should be used.

IMPORTANT: When flued horizontally, the flue pipe must be arranged to provide a continuous rise from the appliance of 25mm per 1m length.

The ventilation requirements for flued appliances are set out in BS 6896:1991 and must be applied. The following is guidance to the standard:

NATURAL VENTILATION Low level ventilation shall be provided in all cases below the level of the heater(s).

Up to and including 60kW: 4.5cm

Over 60kW: 270cm

/kW

+ 2.25cm2 /kW in excess of 60kW total rated heat input.

Where the air supply openings can be closed, it shall only be possible to operate the radiant heaters when they are open.

MECHANICAL VENTILATION Ventilation shall be provided in all cases at or below the level of the heaters.

Minimum proven air flow: 2.35m

/h/kW of total rated heat input.

It shall only be possible to operate the radiant heaters whilst the ventilation airflow is proven.

C. FLUE AND COMBUSTION AIR CONFIGURATIONS

The heaters can be installed with different flue and combustion air configurations please review the diagrams on the following page for the overview of the permitted installations. The permissible maximum lengths associated with these options are listed in the table below.

Table 12 Flue Type

Max Combustion Air 100mm Ø

Max Flue Length 100mm Ø

Max flue length Concentric 150/100mm Ø

Max length combined combustion air

Reduce length for 90° bends 100mm Ø

Reduce length for 90° bends concentric

and flue A2 15m N/A N/A 15m -1.7m N/A B22 13m 15m N/A 28m -1.7m N/A

C C

8m + 1m 8m + 1m 1m + 8m + terminal 9m -1.7m -2.5m

C52 13m 15m N/A 28m -1.7m N/A

-34- Sept 2010

Form #44201150

Page 36

: first length is parallel se ct i o n se cond le n gth i s co ncentric section.

Note

A2 - Fresh air horizontal

A2 - Fresh air vertical

B22 - Fresh air and flue horizontal B22 - Fresh air and flue vertical

B22 - Flue horizontal

C52 - Fresh air & Flue horizontal in different pressure zones

C12 - Fresh air & Flue horizontal in concetric ducts

B22 - Flue vertical

C52 - Fresh air vertical & Flue horizontal in different

pressure zones

C52 - Fresh air horizontal & Flue vertical in different

pressure zones

C12 - Fresh air & Flue horizontal in concetric ducts

C32 - Fresh air & Flue vertical in concetric ducts

Fig. 36

16.1 Type A

Outside (ducted) combustion air supply. When installed in a dusty or polluted atmosphere, the heater

should be fitted with a ducted supply of clean fresh air. A length of 100mm flexible ducting should be installed between the Control Box Air Inlet and any rigid ducting and be secured to the Air Inlet with hose clips. Where outside combustion air is ducted directly to the burner(s) the low level natural ventilation openings shall be not less than 50% of the areas given in 6.4.2.1 above.

16.2 Type B

When installing external flue single duct systems with ducted combustion air supply the distance between

the flue terminal and fresh air intake shall be no less than 1 m for both vertical and horizontal systems

16.3 TypeC

The following figure shows the typical arrangements for concentric sidewall flues, see table 12 for 90°

bend equivalent lengths. The bends shown in the illustrations connecting the combustion air intake to the concentric ducts is calculated into the overall length. For example a system with one additional 150/100mm Ø concentric 90° bend can be installed with 1m 100mm flue single pipe and the combustion air single pipe as shown with 5.5m of 150/100mm Ø straight concentric flue. (8m – 2.5m from table 12)

Form #44201150 Sept 2010 -35-

Page 37

Components

Nr Supplier Description

1. M & G Wall Terminal 150/100mm

2. M & G Concentric vent 150/100mm

3. M & G Flue Single pipe 100mm (Max 8m)

4. M & G Combustion Air single pipe 100mm.

5. M & G Elbow single pipe 100mm (3 shown)

6. Powrmatic Fresh air connector

7. Powrmatic Flue connector

Top View

Side View

ALTERNATIVE:

Use M & G approved flexible connector. For fresh air supply.

Above shows typical arrangement for flue to the side of the heater

End View

Side View

Top View

End View

Above shows typical arrangement for flue to the back of the heater

Fig. 37

-36- Sept 2010

Form #44201150

Page 38

16.4 TypeC32: The following figure shows the typical arrangements for concentric vertical flues, see table 12 for 90°

Components

Nr Supplier Description

1. M & G Roof Terminal 150/100mm

2. M & G Concentric vent 150/100mm

3. M & G Flue Single pipe 100mm (Max 8m)

4. M & G Combustion Air single pipe 100mm.

5. M & G Elbow single pipe 100mm (3 shown)

6. Powrmatic Fresh air connector

7. Powrmatic Flue connector

Section A-A

140mm

ALTERNATIVE: Use M & G approved flexible connector. For fresh air supply.

Fig. 38

16.5 TypeC

When fresh air for combustion and the flue outlet are from different pressures zones as shown in figure 36, the flue outlet and the fresh air intake must not be on surfaces that are 180 degrees apart. The acceptable configurations are those shown in figure 38 in combination with the maximum lengths listed on table 12.

Form #44201150 Sept 2010 -37-

Page 39

16.6 Type C fresh air connector:

The connectors for the Type C fresh air are supplied as an accessory. The installation steps for the Type C connector are shown in figure 38a below.

Step 3. Remove air inlet.

Step 4. Attach with 3 x M6 Nuts

Step 5. Insert pressure test point

Step 1. Remove 3 x M6 Nuts

Step 2. Unscrew pressure test point from inside cabinet.

Leave air plate in place.

Do not unscrew center pressure test point.

air connection

Air plate GasketType C fresh

Step 6. Secure pressure test point with nut inside cabinet.

Fig. 38a

15.0) LIGHTING AND SHUTDOWN INSTRUCTIONS

a. Ensure that the Control Box lid is closed and secured with the two toggle latches. The heater will not operate

with the door open.

b. Turn on the gas supply to the appliance. c. Set any time switches or thermostats to demand heat. d. Switch on the electricity supply to the appliance. The red neon indicator and amber neon indicator will be

illuminated.

e. The burner should ignite within 20 seconds. Both red and amber neon indicators will remain illuminated. f. Failure to ignite will result in the ignition controller going to "lockout" condition. The red neon indicator will

remain illuminated. The amber neon indicator will be extinguished.

g. If lockout occurs, switch off the electricity supply to the appliance; wait for 10 seconds before switching on

the electricity supply to the appliance to repeat the ignition sequence.

h. If the appliance fails to ignite after a second sequence switch off the electrical supply to the appliance and

call the service engineer.

i. If gas failure occurs after successful ignition the appliance will attempt one re-ignition before going to

lockout condition.

j. To shut down the appliance for short periods of time, switch off the electricity supply to the appliance.

-38- Sept 2010

Form #44201150

Page 40

k. To shut down the appliance for longer periods of time, switch of the electricity supply to the appliance and

turn off the gas supply at the gas isolation valve.

NOTE: The lighting and shutdown instructions are also shown on a permanent label attached adjacent to the controls for the heater (see section 9.2).

COMMISSIONING

The chart below shows the sequence of operation for the normal operating cycle.

Thermostat

Blower

Red neon indicator

Air switch

Amber neon indicator

Ignition

Gas valve

Flame sensing

Call for heat, Thermostat on

20 secs pre-purge

10 secs trial for ignition

Normal operation flame sensing

Thermostat off, Heater OFF

T0 T1 T2 T3 T4

Function ON Function OFF

Fig. 39

If the flame is not sensed during sequence T3 then the heater will go to lockout.

It is essential that all new pipework installations are purged and tested for soundness with a suitable leak detection fluid prior to attempting to ignite any appliance. This work should be carried out in accordance with National or Local regulations.

NOTE: DO NOT TEST FOR SOUNDNESS BY USE OF NAKED FLAMES.

16.0) CLEANING AND ANNUAL MAINTENANCE

ELECTRIC SHOCK & EXPLOSION HAZARD

Disconnect electrical power and gas supply before servicing.

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

This heater must be cleaned and serviced annually by a qualified contractor before the start of each heating season and at any time excessive accumulation of dust and dirt is observed. Maximum heating efficiency and clean combustion will be maintained by keeping the heater clean.

It is essential that at least once a year, preferably before the heating season, a qualified person service the appliance. In exceptionally dirty conditions, more frequent servicing may be desirable.

IMPORTANT:

a. Do not rest anything, especially ladders, against the appliance. b. Gas and Electricity supplies must be isolated before commencing servicing work or replacement of

components.

Form #44201150 Sept 2010 -39-

Page 41

c. On completion of a service/fault finding task which has required the breaking and remaking of electrical

corrections, the following checks, using a multi-meter must be made.

1. Earth continuity check

2. Polarity check

3. Resistance to earth check

The contractor shall check the following during periodic maintenance.

• Clearances to combustibles: Check that clearances are being maintained. Make sure there are no

flammable objects, liquids or vapors near the heater. See also Section 4.0).

• Reflectors: Reflectors should be kept clean, at a minimum blow off the reflectors. (Dirty reflectors will

reduce heat output).

• Heat exchanger tubes: Inspect the heat exchanger tubes to make sure they are not cracked, sagging or

showing signs of fatigue.

• Combustion air intake: Disconnect combustion air intake from the control box and inspect internally using a

flashlight to make sure no foreign material has collected in the tubes and that there is no obstruction around the air intake openings. Clean any foreign materials. Inspect any joints to make sure they are completely sealed. See also Section 14.

• Venting System: Disconnect vent pipe and inspect internally using a flashlight to make sure no foreign

material has collected in the pipes. Check the external vent cap and make sure that there is no obstruction around the exhaust openings. Clean any foreign materials. Inspect any joints to make sure they are completely sealed. See also Section 14.

• Gas lines: Make sure that the gas lines are not leaking. Check the gas connection to the heater for any signs

of damage, fatigue or corrosion. If there are any signs of damage to the gas connection or leaks found in the gas piping, immediately stop using the heater until the gas pipe and connections have been repaired or replaced. Check that the gas lines are not bearing the weight of the heater. See also Section 11.

• Burner Box: In order to extend the longevity of the heater, the heat exchanger tube and the burner must be

level. Check that the burner box is level; use the turnbuckle on the burner suspension eyebolt to adjust the level of the burner. See also Section 9.1.

• Blower wheel and housing: Check that the blower wheel spins freely, blow out any dust or dirt with

compressed air.

• Electrode condition: Visually check that the electrode gap is maintained at 3.5mm and that the tips of the

flame sensor and spark electrode are free from deposits. Clean off any deposits. Check that the electrode ceramic is free from cracks. See Section 19.1.

• Suspension system: Check that the suspension system is holding the heater level. Make sure that the heater

is hanging securely, look for any evidence where the heater may have been hit accidentally and tighten any loose hanging points. Check that S hooks are closed. Check that there is no evidence of wear on the chain at the connection to the heater and at the ceiling.

• Main Burner and Orifice: Check the Main burner and orifice; remove any dirt or debris including spider webs.

See Sections 19.2 and 19.3 .

• Electrical Wiring: Check that all the electrical connections are sound and that the wiring is undamaged.

Replace damaged wires as necessary.

• Air Inlet / Baffle Plate: Check that the air inlet holes in the Baffle Plate, which is clamped between the

Control Box side panel and the Air Inlet flange, are clear from obstructions. Check also, that the wire mesh panel of the Air Inlet is clean. Clean as necessary using a soft brush. In the case of an appliance having a ducted air supply, it will be necessary to disconnect the flexible ducting from the Air Inlet by first releasing the hose clip. If it is necessary to remove the Air Inlet to adequately clean the Baffle Plate it will be necessary to replace the gasket seal (see Section 19.8.

• Door Seal: Check the condition of the seal around the Control Box door and replace as necessary.

IMPORTANT: The appliance will not function unless the seal around the control box door is sound and the door secured with the two toggle latches.

• Flue Pipes: For flued appliances it is important that periodic sweeping of the flue is carried out according to

the National or Local regulations in force.

• Auxiliary Controls: Room thermostats, time switches, frost thermostats etc should be checked to ensure

correct functioning, and are set to the user requirements.

• Re-assemble and Commission: Re-assemble the appliance in reverse order and commission in accordance

with the instructions contained in Section 16.0.

-40- Sept 2010

Form #44201150

Page 42

17.0) TROUBLESHOOTING GUIDE

Replace amber neon

indicator.

Yes

Replace the red neon

indicator.

Yes

Is there 230V across

terminals on the red

neon indicator?

Yes

Are the brown lead

wire and blue lead

wire terminals

securely on the red

neon indicator?

Restart

troubleshooting.

Repair connection.

Replace motor

Disconnect the power

and check motor lead

wires. Any wire

broken?

Yes

Repair broken wires.

Check the continuity

between terminal 5

and terminal L to fan.

Repair connection if

necessary.

Yes

Is there 230V

between terminal 5 of

the terminal block of

the ignition module

and earth?

Yes

Replace ignition

module.

Jumper the NO and

COM at air switch.

Does the amber neon

indicator come on?

Yes

Is their any blockage

in the fresh air duct or

in the exhaust venting

duct?

Yes

Is the air hose

properly installed

between air switch

and test nipple on air

plate?

Yes

Check the blue wire

connection between

amber neon indicator

and terminal block. Is

there any loose

connection?

Replace air switch.

Remove blockage.

Repair connection.

Yes

Is there any loose or

wrong connection at

the terminal block in

the control box?

Yes

Is there 230V

between L and N on

Power In section of

the terminal block in

Turn on power and

thermostat. Does the

red neon indicator

come on in the control

Repair connection.

Check power voltage

the control box?

box?

at thermostat and

repair fault.

Yes

Form #44201150 Sept 2010 -41-

Is there 230V

between L and N on

Fan section of the

terminal block in the

control box?

Yes

Are there any loose

or wrong wire

connections at the

fan?

Is the fan on?

Is the terminal block

properly connected to

the ignition module?

Repair connection.

Check the violet wire

connection between

amber neon indicator

and air switch. Is there

any loose

Yes

Are the violet lead

wire and blue lead

wire terminals

securely on the amber

neon indicator?

Yes

Does the amber neon

indicator come on in

the control box?

Yes

connection?

Repair connection.

Yes

Troubleshooting

continued on the next

page.

Note: when troubleshooting inside the control box, shut off gas valve and restart the power to the control box. Othewise, the control box should be installed with its lid.

Page 43

Replace the ignition

module & ignition

cable.

Yes

Call factory for

assistance.

Yes

Turn on all gas shut

off valves upstream

the control box.

Yes

Correct the setting.

Yes

Is the spark gap

3.5mm?

Adjust the spark gap

to 3.5mm.

Clear the blockage at

the orifice.

Yes

Is the ceramic

insulator OK on the

spark electrode?

Shut off gas supply,

jumper air switch

COM and NO, and

call for heat. After 20

Yes

Is the green/yellow

wire securely

connected to the

electrode and earth?

Yes

Is the grey wire

securely connected to

the ignition module

and the electrode?

Yes

Replace the spark

electrode.

Yes

seconds, is there

continuous sparking?

Repair connection.

After an initial step

opening, is the

manifold gas pressure

correct?

Yes

Check orifice and

holder for blockage

(i.e. spider web). Is

there any blockage?

Yes

Check the manifold

gas pressure during

startup. Is it zero

inches?

Yes

Check the inlet

pressure to the gas

valve. Is it between

minimum and

maximum for the gas

type?

Yes

Adjust manifold gas

pressure. Restart

troubleshooting.

Clear blockage.

Replace gas valve.

Adjust supply gas

pressure.

Restart

troubleshooting.

Troubleshooting

continued from the

previous page.

Check the gas supply

to the control box. Is

gas pressure greater

than the minimum for

the gas type?

30 seconds after

startup, does the

amber neon indicator

stay on in the control

box?

Is the step opening

setting correct?

Is the orifice blocked?

Is the ignition module

properly connected to

the gas valve inside

the control box?

Repair connection.

Has all the air been

purged from the gas

supply lines?

Yes

Troubleshooting ends.

Check the spark gap.

Is it 3.5mm?

Purge the gas supply

line.

Adjust the spark gap

to 3.5mm.

-42- Sept 2010

Form #44201150

Page 44

18.0) REPLACING PARTS

ELECTRIC SHOCK & EXPLOSION HAZARD

Disconnect electrical power and gas supply before servicing.

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

Only use genuine Powrmatic replacement parts. Parts are available from the factory for replacement by a licensed person. Refer to the Replacement Parts Guide in Section 21.0) for all replacement parts.

IMPORTANT: Disconnect gas and electricity supplies to the appliance before carrying out any repair work. This work can be carried out at high level using a purposes designed access tower, but it is preferable that this work should be carried out at ground level.

18.1) REMOVAL OF ELECTRODES

2,5

Fig. 40

3.5mm Spark Gap

This range of radiant tube heaters employs a single probe electrode system whereby both the spark generation and flame supervision operations are carried out via a common electrode. The second electrode provides the earth path for the ignition spark. The two electrodes are identical, therefore either lead (grey HT or green/yellow earth) may be connected to either electrode.

1. Open the Control Box door after releasing the two toggle latches.

2. Disconnect the grey HT ignition/flame sensor lead and the green/yellow earth lead from the electrodes

by gently pulling the connectors, using pliers.

3. Unscrew the M6 x 16 set-screw securing the electrode carrier to the Control Box and remove the

Electrode Assembly.

4. Remove any foreign matter from the Electrode tips and check that the spark gap is 3.5mm. If the

Electrode rods are badly oxidized, replace the electrodes.

5. Upon re-assembly, ensure that the HT lead and earth lead connectors are securely attached to the

Electrodes.

Form #44201150 Sept 2010 -43-

Page 45

18.2) REMOVING MAIN BURNER

Fig. 41

1. Open the control box door; unscrew the two M4 x 25 setscrews from the Burner Bracket and remove the

Burner Clamp.

2. Unscrew the Burner from the Injector Fitting

3. Lift the burner out of the Control Box.

4. Clean by use of a stiff brush to remove any deposits.

18.3) REMOVING INJECTOR

Fig. 42

1. Remove the Burner as described at above. Unscrew the Injector from the Injector Fitting, using a

spanner, whilst retaining the Injector Fitting with a second spanner.

2. Inspect the Injector and clean as necessary with a soft bristle brush.

DO NOT DAMAGE THE INJECTOR ORIFICE BY USE OF SOLID OBJECTS.

-44- Sept 2010

Form #44201150

Page 46

18.4) REMOVING IGNITION CONTROL

Fig. 43

1. Disconnect the 12 way Molex electrical connector and the grey HT ignition spark/flame sensor lead

from the Ignition Control.

2. Unscrew the M3 screw securing the Ignition Control to the Control Valve.

3. Slide out the Ignition Control.

18.5) REMOVING AIR SWITCH

1 (H)

Fig. 44

1. After opening the control box door, remove the Air Tube Assembly from the Air Switch pressure

connection marked 'H'.

2. Disconnect the three electrical leads from the Air Switch by gently pulling the connectors, using pliers.

3. Unscrew the two No. 8 x 12 self tapping screws securing the Air Proving Switch to the floor of the Control

box and lift out with the electrical leads attached.

4. Remove the Air Switch, and remove the restrictor from the Air Switch connection marked 'L'.

When installing a replacement Air Switch, take care to connect the electrical leads in accordance with the wiring diagram shown in (Section 13.0) and replace the restrictor on the pressure connection marked “L”. The appliance will not function unless this restrictor is in place

Form #44201150 Sept 2010 -45-

Page 47

18.6) REMOVING GAS VALVE AND MANIFOLD ASSEMBLY

Fig. 45

1. After opening the control box door, disconnect the 12 way Molex electrical connector.

2. Disconnect the grey HT ignition spark/flame sensor lead from the ignition module.

3. Unscrew the two M4x25 setscrews from the burner bracket and remove the burner clamp.

4. Unscrew the burner and slide it away from the valve.

5. Unscrew the M4 screw securing the valve bracket to the control valve and remove the grommet.

6. Slide out the complete assembly of gas valve, ignition module and manifold.

After replacing the Control Valve, check the gas pressures in accordance with Section 12.0) of this manual.

IMPORTANT: TEST FOR GAS SOUNDNESS USING A SUITABLE LEAK DETECTION FLUID.

18.7) REMOVING NEON INDICATOR

Fig. 46

1. Disconnect the electrical leads from the Neon Indicators by gently pulling the connectors, using pliers.

2. Remove the star washers.

3. Press the neon indicator out through the mounting hole in the floor of the control box.

When replacing a Neon Indicator, connect the electrical leads in accordance with the wiring diagram shown in (Section 13.0)

-46- Sept 2010

Form #44201150

Page 48

18.8) REMOVING AIR INLET PLATE

Gasket

Hex Nuts & Washers (3 each)

Baffle Plate

Pressure

Front View (access panel removed)

Air Inlet Assembly

Air Switch Pressure Test Fitting

Test Fitting

Fig. 47

1. After opening the control box door, disconnect tubing from both brass pressure test fittings.

2. Remove brass nut from pressure test fitting.

3. Disassemble components from the control box.

18.9) REMOVING THE FAN

Fan Unit

Gasket

Air Restrictor Plate

Connector - (0 101.6mm)

Torctite Coupling

Radiant Tube

Connector - (0 76.2mm)

Fig. 48

1. Disconnect the electrical wires from the fan (see Section 13.0) for connection details.

2. If a flued installation, disconnect the flue from the Fan.

3. Loosen the nuts of the Torctite Coupling securing the Fan Connector to the Radiant Tube and draw the

Fan Assembly off the Radiant Tube.

4. Unscrew the three M6 x 12 setscrews securing the Connector and Orifice Plate to the fan.

5. Inspect the main impeller and secondary cooling impeller and remove any dust by brushing with a soft

brush. Check that the impeller rotates freely and that there is no excessive play in the bearings. The bearings are pre-lubricated and require no attention.

6. When re-assembling the Orifice Plate and Connector, a new Gasket must be fitted between the Fan

housing and Orifice Plate (see Fig. 48).

Form #44201150 Sept 2010 -47-

Page 49

19.0) CONVERSION INSTRUCTIONS

CONVERSION FROM CAT. 2H (Natural Gas) TO CAT. 3P (LPG)

a. Remove the Injector from the Injector Fitting (see Section 18.3) and replace it with the alternative Injector

supplied with conversion kit. Check that the size reference marked on the Injector agrees with that listed in the Specifications table (Section 5.0) for the appliance model in question.

b. Remove the pressure governor cap from the integral pressure governor of the Control Valve and screw the

adjuster clockwise to increase the gas pressure, check supply and manifold pressure in accordance with Section 11. Replace the pressure governor cap.

c. Affix the gas adjustment label (3P G31 37mbar) supplied with conversion kit onto the Data Label, adjacent

to the headings "Adjusted For" and "Setting Pressure", to cover the original gas adjustment label (2H, G20, 20mbar).

d. Carry out checks in accordance with Section 11 of this manual to ensure correct supply pressure relative to

the gas type being used (G31 – Propane).

CONVERSION FROM CAT. 3P (LPG) TO CAT. 2H (Natural Gas)

a. Remove the Injector from the Injector Fitting (see Section 18.3) and replace it with the alternative Injector

supplied with conversion kit. Check that the size reference marked on the Injector agrees with that listed in the Technical Data table (Section 5.0) for the appliance model in question.

b. Remove the pressure governor cap from the integral pressure governor of the Control Valve and unscrew the

adjuster counter clockwise to increase the gas pressure, check supply and manifold pressure in accordance with Section 12.0). Replace the pressure governor cap.

c. Affix the gas adjustment label (2H, G20, 20mbar) supplied with conversion kit onto the Data Label adjacent

to the headings, "Adjusted For" and "Setting Pressure" to cover the original gas adjustment label (3P, G31, 37mbar).

d. Carry out checks in accordance with Section 12.0) of this manual to ensure correct supply pressure and

setting pressure, relative to the gas type being used (G20 - Natural Gas).

20.0) INSTALLATION DATA

Date of Installation:

Serial No.

Model:

# of Heaters in

System:

N = Natural Gas L = Propane Gas

-48- Sept 2010

Form #44201150

Page 50

21.0) REPLACEMENT PARTS GUIDE

The following is a list of replacement parts which may be required during the life of the appliance.

CONTROL COMPONENTS

Item No. Part No.

1 02330010 Vinyl Cap 1 2 02331010 Plug, Liquid Tight Hole 1 3 4262151 I nlet – Male Pin #PX0575 1

3a 4262153 Outlet – Female #PX0695 1

4 30700040 Grommet, Pipe Sealing 1 5

6 42602870 Housing (welded) 1 7 4250694 Access Panel (with hinge) 1 8 44202000 Turnbuckle Holder Bracket 1

8a 30545040 Turnbuckle (Not shown) 1

9 03988070 Tubing, Silicone – 178mm Lg. (Not shown) 2 10 2113 Pressure Test Point 1 11 4260363 Test Nipple 1 12 4262322 Brass Locknut 2

13 4250600 Burner Fabrication 1

13a 42700000 Burneer (25kw controls only)

14 4250625 Air Switch Assembly 1 15 4250696 Gas Valve Assembly (complete) 1

15a 4262586 Gas Valve #VK4105C 1 15b 426255 2 Flange, 1/2 BSPT - Straight 1

15c 4260502 Pipe Nipple, 1/2 BSPT x 110mm 1 15d 4260382 Valve Bracket 1 15e 426255 1 Flange, 1/2 BSPT - Elbow 1

16 42506950 Wiring Harness – less HI Tension Cable (Not shown) 1 17 42510929 Hi Tension Cable – 178mm Lg. (Not shown) 1 18 4260132 Gasket 2

19 4260364 Injector Fitting – 1/2 BSPT x 7/8 UNF 1 19a 42701000 Injector Fitting – 1/2 NPT x 5/8 UNF (25kw controls only) 1 19b 03540090 Coupling – 1/2 NPT (25kw controls only) 1

19c 03333040 Pipe Nipple, 1/2 NPT x 38mm (25kw control only) 1

20 4260367 Burner Clamp 1

21 4260370 Connector – 76.2mm (shown) 1 21a 4260371 Connector – 101.6mm 1

22 4260380 Burner Bracket 1

23 4260541 Electrode 1

24 4262197 Ignition Control 1

25 4262280 Neon Light - Red (round) 1

26 4262281 Ne on Light - Amber (round) 1

27 xxxxxxxx Gas Injector (State Model & Gas Type for Size) 1

28 4260360x Baffle Plate (State Model & Gas Type for Size) 1

29 4260362 Air Inlet Fabrication 1

Description

Qty.

Form #44201150 Sept 2010 -49-

Page 51

LABELS/MANUAL

Item No. Part No.

30 4262036 Label Neon 1

31 4262035 Label, Fan/Power Supply 1

32 4260420 Label, Warning - GB/IE 1

33 43344130GB Label, Clearances to Combustibles 1

34 42848180GB Label, Nameplate 1

35 4260440 Label, Operating Instructions - GB 1

36 Label, Powrmatic Logo 1

37 44201150 Installation/Operation Manual 1

Description

Qty.

Fan Assembly

Item No. Part No.

1 4262256 Fan Unit – Airflow #45BTFR 1 2 4260132 Gasket 1 3 42741170 Air Restrictor Plate (76.2mm dia. opening) 1

4 4260370 Connector – (for 76.2mm dia. tube) 1 5 4260371 Connector – (for 101.6mm dia. tube) 1

6 44200010 Flue Screen Outlet Plate - 103 x 113mm (accessory) 1 7 4267261 M6 x 16mm Hex Head Setscrews 6

7a 4267266 M6 Spring Lockwashers 6

Description

Qty.

-50- Sept 2010

Form #44201150

Page 52

Form #44201150 Sept 2010 -51-

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

Specifications and Main Features

Frequently Asked Questions

User Manual