Powrmatic CP series Manual

CP Range
Users, Installation & Servicing Instructions
Gas & Oil Fired Heaters
CE
WARNING: THIS A LIANCE MUST BE EARTHED
CP(2007) Range Issue 3.5 July 2009
TESTED
Full mechanical, construction, assembly and electrical sequence check
Full functional test in accordance with Quality System rocedures
Heater Model
Heater Serial No.
Fuel Type

Dear Customer
This is to certify that this appliance is guaranteed for two years including parts and
labour from the date of original commissioning.
The heat exchanger, where fitted, is guaranteed (parts only) for a further eight years,
chargeable on a sliding scale basis, price relative to age.
To make a claim
In the first instance you must contact your appliance supplier, or installer and
provide:
1. The appliance type and serial number.
2. The original commissioning documentation.
3. As much detail as possible on the fault.
Your supplier, or installer will then contact Powrmatic to make a guarantee claim
on your behalf.
Conditions of Guarantee
1. The appliance must have been installed by a competent recognised installer,
and in accordance with the manufacturers instructions, building regulations and
local regulations.
2. The appliance has been professionally commissioned.
3. The appliance has been maintained on a yearly basis by a competent servicing
company.
4. The appliance has been used in accordance with the manufacturers instructions.
5. The correct specification fuel has been used
6. No unauthorised repairs or modifications have been made.
7. Powrmatic General Conditions of Sale have been observed.
8. Except for the obligation of Powrmatic Ltd to perform warranty repairs during
the guarantee period, Powrmatic will not be liable in respect of any claim for
direct or indirect consequential losses, including loss of profits or increased costs
arising from loss of use of the appliance, or any event arising there from.
Exclusions
1. Gaskets and fan belts are not included in the guarantee
Important: This certificate must
be kept with the appliance
Certificate of Guarantee
Powrmatic Ltd, Hort Bridge, Ilminster, Somerset, TA19 9PS
tel: [phone] fax: [phone]
web: www.powrmatic.co.uk

1. Checks before lighting the Air Heater
The following chec s should be made before lighting the heater(s)
a) Ensure the electrical supply to the heater is switched OFF.
b) Chec that all warm air delivery outlets are open.
c) Chec that the thermostat is set at MAX.
d) Chec that the cloc control is set to an ON period.
e) Chec that any other controls are calling for heat.
f) Ensure the Summer/Winter switch (fitted on the Powrtrol) is
in the Winter position.
g) Chec that the overheat reset button has not operated.
2. Lighting the Air Heater
2.1 Gas-fired Heaters
1. Switch on the electrical supply at the isolator and the burner
start-up sequence will commence. The burner air fan will run
and after a pre purge period of approximately 30 seconds the
ignition spar will be generated.
CP 100 - 300
The main gas valves will open and the main burner will be
established
CP 400 - 2000
The start gas valves will be opened and a start gas flame
established. When a start gas flame is established the main gas
valves will be energized and the start gas flame will expand to
main flame.
NOTE: If the main burner or a start gas flame fails to establish
the burner will go to loc out and the loc out indicator / reset
button on the burner control box will be illuminated. To restart
the burner push the loc out reset button. Additional, more easily
accessible, controls may be fitted that mimic the loc out indicator
and reset button functions.
If the unit will not light after four or five attempts then shut
down the unit and call in a service engineer.
2.2 Oil-fired Heaters
NOTE: If it is not possible to light the heater after 2/3 attempts
contact the local service company.
1. Switch on the electrical supply at the isolator and the burner
start-up sequence will commence. The burner air fan will run
and after a pre purge period of approximately 30 seconds the
ignition spar will be generated and the oil valve opened.
The main burner will then start.
NOTE: If the burner fails to light it will go to loc out and the
loc out indicator / reset button on the burner control box will
be illuminated. To restart the burner push the loc out reset
button.
3. To Shut Down the Air Heater
3.1 For Short Periods:
Turn the room thermostat to the OFF or lowest setting.
3.2 For Long Periods:
Turn the room thermostat to the OFF or lowest setting.
Wait approximately 4-5 minutes for the main air fan of the
heater to stop running and the turn off the gas or oil supplies
and electric supplies to the heater.
4. Description of Operation
Important: All heaters must be controlled by the fitted external
controls and not by use of the main switch in the electrical
supply to the heater.
The burner start up sequence will commence when the controls
e.g. Timecloc , room thermostat etc. call for heat. The burner
air fan will run and after a pre purge period the burner will light.
Approximately 2/3 minutes after the burner lights the heater fan
Users Instructions
will automatically start. When the external controls are satisfied
the burner will be turned off and approximately 4/5 minutes
later the heater fan will automatically stop.
4.1 Summer / Winter Modes
Certain types of external controls will provide for two modes
of operation i.e.
Summer: The heater fan alone will run at the dictate of the
external controls to provide air movement.
Winter: The heater will operate normally.
5. Fan and Limit Control
The fan and limit controls are mounted towards the top of the
air heater upper front panel.
5.1 C 100 - 1000
i) Main Air Fan MAN / Auto
When the white button (Refer to Figure below) is pushed in
the fan will run continuously i.e not controlled by any external
controls e.g. Timecloc . When the white button is pulled out
the fan will start and stop automatically in conjunction with
the burner. See Section 4.
ii) Limit Thermostat Reset
In the event of a fault that causes the temperature of the air
leaving the air heater to rise significantly e.g. Bloc ed air inlets,
the limit thermostat will operate to shut down the burner.
Remove the cause of the fault, wait 10 minutes and then reset
the thermostat by pushing the red reset button (Refer to Figure
below) .If the limit thermostat continues to operate turn off the
air heater and call a service engineer.
USH TO
RESET
USH MAN
ULL AUTO
Honeywell
Red
reset
button
Fig 1. Limit Thermostat C 100 - 1000
White
Fan
button
6. Maintenance
Regular servicing is essential to maintain efficient, reliable and
safe operation of the heater. Users are strongly recommended
to have the heater serviced at least annually and preferably at
the end of the heating season.
7. IM ORTANT
Free access must be maintained to and around the heater for
servicing purposes and the air supply to the heater must not be
restricted in any way. Combustible materials must not be stored
adjacent to the heater.

All Powrmatic heaters use gas and electricity to power them,
they may also contain moving parts such as pulley belts. It
would be hazardous to tamper with or attempt to service unless
you are a competent person in the field of Gas and Electrical
wor .
If you have any safety questions reference the servicing and
installation of any of our heaters please do not hesitate to contact
our head office for expert advice.
Your safety is paramount to us.
For gas fired heaters:
If at any time a gas lea is suspected turn OFF the gas supply
- DO NOT USE A NAKED FLAME - and contact the local gas
underta ing immediately.
Gas Safety (Installation & Use) egulations
It is law that all gas appliances are installed, adjusted and, if
necessary, converted by qualified persons* in accordance with
the above regulations. Failure to install appliances correctly
can lead to prosecution. It is in your own interests and that of
safety to ensure that the law is complied with.
** An approved class of person listed on the gas register.

Section Title Page
1. Introduction 4
2. Technical data 5
3. General requirements 9
4. Installation of air heater(s) 10
5. Commissioning & testing 13
6. Servicing 15
7. Fault finding 17
8. Short list of parts 17
Appendix A 18
Table Title Page
1. Dimensions 7
2. Specifications 7
3. Electrical Data 7
4.1 Burner ressures for Natural Gas - Groupe H  Type G20 8
4.2 Burner ressures for ropane  Type G31 8
5. ump ressures for 35sec fuel oil 8
Diagram Title Page
1. Minimum clearance dimensions 10
2. Dungs valves - pressure adjustment 13
3. Fan belt tension setting 15
4. Thermostat Fan / Limit - Honeywell L4064N 16
5. Thermostat Fan / Limit - White Rodgers 5F464 16
Index
3
Installation & Servicing Instructions

1. INT ODUCTION
The Powrmatic CP range of closed flue, fanned circulation air
heaters cover a heat output range of 29.3 W to 586.1 W and
are intended primarily for heating commercial or industrial
premises. They are fitted with either a gas fired forced draught
burner or a pressure jet oil fired burner.
Gas fired units are certified for use on Natural Gas, Group H
- G20, Group L - G25 and Propane - G31.
Oil fired units are supplied as standard for use with 35sec fuel
and can be supplied for use with 28sec fuel as an option.
CP heaters have a centrifugal fan assembly fitted upstream of
the combustion chamber / heat exchanger assembly to circulate
the air being heated.
CP heaters are available in three styles:
Standard Style
Suitable for internal applications only and available in /UF,
/UD, /HD, /HF, /CF and /CD variants (see below). /UF and /UD
models are floor standing, /HD, /HF, are horizontally mounted
on purpose design supports. /CD models can be plinth mounted
at floor level. /CF and /CD models can be mounted at high level
on purpose design supports.
CP/NCA Style
Suitable for internal applications only and having an extended
casing that encloses the burner. Available in /UF and /UD
variants only(see below).
CP/EA Style
Casing is extended to enclose the burner. The heater is fully
weatherproof and designed for external applications only.
Available in /TD, /HD, /RT and /SD variants (see below).
Variant types are:-
/UF - Upright heater with free blowing rotatable heads.
/UD - Upright heater with outlet duct spigot (inlet duct spigot
optional).
/HF - Horizontal heater with free blowing rotatable heads.
/HD - Horizontal heater with outlet duct spigot (inlet duct spigot
optional).
/CF - Counterflow heater with free blowing rotatable heads.
/CD - Counterflow heater with outlet duct spigot (inlet duct spigot
optional).
/TD - Rooftop heater with top outlet duct spigot (inlet duct spigot
optional).
/RT - Rooftop heater with outlet duct spigot on the underside
(inlet duct spigot optional).
/SD - Upright heater with side outlet duct spigot (inlet duct spigot
optional).
Other options include High/Low or modulating burners, uprated
main fan motors, flue support brac et, deep V filters, flat panel
filters, proportional air dampers, combustion air inlet adaptors
and inlet and outlet duct spigots.
Each air heater must be connected to a closed flue system only.
For gas fired heaters
Gas Safety (Installation & Use) egulations
It is law that all gas appliances are installed, adjusted and, if
necessary, converted by qualified persons* in accordance with
the above regulations. Failure to install appliances correctly
can lead to prosecution. It is in your own interests and that of
safety to ensure that the law is complied with.
* * An approved class of person listed on the gas register.
4
Installation & Servicing Instructions

x
J height
x
H width
2. TECHNICAL DATA
C 100 - 1250
Front View
as /UF
Side View
as /UF
Rear View
as /UD (with optional inlet duct spigot)
C
D
B A
F
E
G height
J width
x
H length
Standard Style ( P300 Shown)
/EA Style ( P300/EA Shown)
Plan View
as /HD (with optional inlet duct spigot)
Front View
as /HF
C
D1
H width
B
Front View
as /RT (with optional weathered inlet hood)
G length
x
H width
L length
x
H width
C
D2
B
F
A
5

6
x
H width
Front View
as /UF
Side View
as /UF
Rear View
as /UD (with optional inlet duct spigot)
G height
J width
x
H length
/NCA Style ( P300/N A Shown)
F
E
RH Side View
as /SD (with return air inlet duct spigot)
LH Side View
as /SD (with fresh air inlet louvre)
C
D2
A
Top View
as /UD
H
J
x
H width
x
H width
Front View
as /SD
B
G height
K height
/EA Style continued ( P300/EA Shown)
F
F
Note: CP 1500 and CP 2000 heaters ha e front flue outlets

7
Table 3. Electrical Loadings
C 800
C 500
C 400
C 600
C 700
C 1000
C 100
C 2000
C 1250
C 1500
C 200
C 300
C 150
Table 1. Dimensions
Model AA
NCA& EA BCD EFGHJK
340
443
150
1362 1262
D1
728 600 1644 304 1386 125 482 628 500 300246 1130
2737 1695 3016 2616 1593 700 3537
1058 958 1550
1854
2043
2191
2151 175
2451 738
300 655 2332
1158 2037 200 1058 580
350255 206
904 803 400280
1667 15673502348
13912432 2788 2420 1291 670 3200
804 626 1822 1553 125 581 703 5241255
728855 2074 1907 637 755 6281307
For CPO150 see CP100 above, for CPG150 see CP200 below (For /E variant CPG150 see CPG100)
Table 2. Specifications
Fan motor
Gas Oil
Model
Input
(Nett) Air
Volume Standard
Motor
Uprated
Motor
Output
Maximum duct
resistant
Standard
Motor
Uprated
Motor
Kw m³/s pa Kw
Weight
Fuel
Connection
Size
Kg
C C /NCA C /EA
C 400 Rc¾330133.7 117.2 2.0766 150 N/A 2.2 N/A ¼BSP 448 458
C 1000 333.1 Rc1½ 556293.1 5.1919 50 100 5.5 7.5 BSP 828 845
C 1500 439.6511.0 Rc1½ 1397
7.7880 200 250 2 x 4.0 2 x 7.5 BSP 1471 1502
C 200 67.0 58.6 1.0383 200 N/A 0.560 N/A Rc¾ 163¼BSP 210 215
C 300 88.0103.0 1.5575 250 N/A 1.5 N/A Rc¾ 204¼BSP 304 304
C 500 168.9 146.5 2.9736 210 240 2.2 3.3 Rc¾ 355¼BSP 535 546
C 600 202.3 175.8 3.4000 190 250 3.3 5.5 Rc¾ 435¼BSP 548 560
C 700 237.8 205.1 3.9647 100 200 4.0 5.5 Rc1½ 530¼BSP 561 573
C 800 266.5 234.5 4.5075 N/A 150 3.3 5.5 Rc1½ 550BSP 615 628
C 1250 6.4866413.8 366.4 300 N/A 11.0 N/A Rc1½ 670BSP 985 1005
C 2000 678.7 586.2 10.3840 155 250 2 x 7.5 2 x 11.0 Rc2 1930BSP 3235 3302
C 100 149 15032.1 29.3 Rc½0.5192 N/A 0.335 N/A 126¼BSP 152
C 150 48.4 44.0 PO150 see P100, PG150 see P200
0.7788 290 N/A 0.550 N/A
Model
C 400
C 1000
C 1500
C 200
C 300
C 500
C 600
C 700
C 800
C 1250
C 2000
C 100
C 150
Standard Motor Uprated Motor
ph
1
3
Nominal
Motor
R. .M.
1000
1500
1000
1500
Nominal
Motor
R. .M.
1500
Start
Amps
(A)
N/A
25.0
35.0
35.0
35.0
32.0
Run
Amps
(A)
5.75
11.0
8.83
11.65
14.4
Fuse
Rating
(A)
10
15
15
15
15
Start
Amps
(A)
5.0
8.5
10.0
12.0
14.0
24.0
30.0
35.0
25.0
35.0
33.0
Run
Amps
(A)
4.0
5.9
5.5
7.7
6.0
5.4
6.5
7.6
6.1
11.3
19.0
Fuse
Rating
(A)
5
7
7
10
10
10
10
10
10
15
20 N/A
2 x 33.0 2 x 8.0 20
2 x 46.0 2 x 16.0 35
2 x 48.0 2 x 15.5 35
2 x 70.0 2 x 22.0 50
2635
Gas
Connection
Size
0.5
0.75
1.25
1.5
Oil
Connection
Size
3/8
D2
448
498
643
728
T.B.A.

Table 4.1 Burner ressures - Natural Gas - Group H - G20 - Net CV (Hi) = 34.02MJ/m³
Riello Burners
Start Gas Main Burner
Model Type Pressure Pressure Gas Rate
mbar mbar m³/h
CP-G 100 GS N/A 4.3 3.40
CP-G 1 0 GS 10 N/A 4.2 .12
CP-G 200 GS 10 N/A 3.7 7.08
CP-G 300 GS 10 N/A .2 10.89
CP-G 400 GS 20 2.4 .0 14.14
CP-G 00 GS 20 3.4 6.3 17.86
CP-G 600 GS 20 2.4 .3 21.39
CP-G 700 GAS 3 2. 6.7 2 .1
CP-G 800 GAS 3 1.1 7.8 28.20
CP-G 1000 GAS 3 3.3 9.4 3 .2
CP-G 12 0 GAS 0.7 8.2 43.78
CP-G 1 00 RS 0 0.7 .6 4.00
CP-G 2000 GAS Refer to Powrmatic 71.82
Table 4.2 Burner ressures - ropane Gas - G31 - Net CV (Hi) = 88.0MJ/m³
Riello Burners
Start Gas Main Burner
Model Type Pressure Pressure Gas Rate
mbar mbar m³/h
CP-G 100 GS N/A 3.1 1.31
CP-G 1 0 GS 10 N/A 6.4 1.98
CP-G 200 GS 10 N/A 4.1 2.74
CP-G 300 GS 10 N/A 8.3 4.21
CP-G 400 GS 20 2. .9 .47
CP-G 00 GS 20 3.7 8. 6.90
CP-G 600 GS 20 3.1 8.9 8.27
CP-G 700 GAS 3 2.9 12.9 9.72
CP-G 800 GAS 3 3.0 18.2 10.90
CP-G 1000 GAS 3 2. 17. 13.62
CP-G 12 0 GAS 2.8 18.0 16.92
CP-G 1 00 GAS 2.8 18.0 20.43
CP-G 2000 GAS Refer to Powrmatic 27.24
Table 5 ump ressures - 35sec Oil - Net CV (Hi) = 42.69MJ/kg
Riello Burners
Nozzle Pump
Model Type Make Size Angle Type Pressure
° bar
CP-O 100 G Danfoss 0.60 80 S 14.3
CP-O 1 0 G10 Danfoss 1.0 60 S 12.2
CP-O 200 G10 Danfoss 1.2 60 S 12.9
CP-O 300 G10 Danfoss 2.0 60 S 13.6
CP-O 400 G20S Danfoss 2. 60 S 13.6
CP-O 00 G20S Danfoss 3.0 80 H 14.3
CP-O 600 G20S Danfoss 3.7 60 B 14.3
CP-O 700 G20S Danfoss 4. 60 B 13.6
CP-O 800 Press GBV Danfoss .0 4 B 14.3
CP-O 1000 Press GBV Danfoss 6.0 4 B 1 .0
CP-O 12 0 RL38 Danfoss 4. 60 B 14.3
CP-O 1 00
CP-O 2000 Refer to Powrmatic
Refer to Powrmatic
8

3. General Requirements
3.1 Gas Fired Heaters
3.1.1 Related Documents
The installation of the air heater(s) must be in accordance with
the rules in force and the relevant requirements of the Gas Safety
Regulations, Building Regulations and the I.E.E. Regulations
for Electrical Installations.
It should also be in accordance with any relevant requirements
of the local gas region, local authority and fire authority and
the relevant recommendations of the following documents.
Institution of Gas Engineers & Managers
IGE/UP/1 (Ed.2) Strength and tightness testing and purging
of industrial and commercial gas installations.
IGE/UP/1A (Ed.2) Soundness testing and direct purging of
small low pressure industrial and commercial gas installations.
IGE/UP/1B (Ed.2) Tightness testing and direct purging of small
Natural Gas installations.
IGE/UP/2 Gas installation pipewor , boosters and compressors
on industrial and commercial premises.
IGE/UP/4 (Ed.2) Commissioning of gas fired plant on industrial
and commercial premises.
IGE/UP/10 (Ed.3) Installation gas appliances in industrial and
commercial premises.
British Standards Code of Practice
BS 5588 Fire precautions in the design and construction of
buildings.
Part 2 : 1985 Code of Practice for Shops
Part 3 : 1983 Code of Practice for Office Buildings
BS 6230: 1991 Installation of Gas Fired Forced Convection
Air Heaters for Commercial and Industrial Space Heating.
Those appliances having a gross input rating not exceeding
60 W viz. CPG100 - 150 inclusive and installed so as to ta e
their combustion air from within the building must be installed
in accordance with the relevant recommendations of the following
document.
BS 5440 Flues and Air Supply for gas appliances of rated input
not exceeding 60 W (1st and 2nd family gases), Part 2 - Air
Supply
Reference should also be made to
BS 5864. Code of Practice for installation of gas-fired ducted-
air heaters of rated input not exceeding 60 W.
3.1.2 Service ipes
The local gas underta ing should be consulted at the installation
planning stage in order to establish the availability of an adequate
supply of gas. An existing service pipe must not be used without
prior consultation with the local gas underta ing.
3.1.3 Meters
A gas meter is connected to the service pipe by the local gas
underta ing or a local gas underta ing contractor. An existing
meter should be chec ed, preferably by the gas underta ing, to
ensure that the meter is adequate to deal with the total rate of
gas supply required.
3.1.4. Installation ipes
Installation pipes should be fitted in accordance with
IGE/UP/2. Pipewor from the meter to the air heater must be
of adequate size. Do not use pipes of a smaller size than the
inlet gas connection of the heater. The complete installation
must be tested for soundness as described in the above Code.
3.1.5. Boosted Supplies
Where it is necessary to employ a gas pressure booster the
controls must include a low pressure cut off switch at the booster
inlet. The local gas underta ing must be consulted before a gas
pressure booster is fitted.
9
3.2 Oil Fired Heaters
3.2.1 Related Documents
The installation of the air heater(s) must be in accordance with
the rules in force and the relevant requirements of the Building
Regulations and the I.E.E. Regulations for Electrical Installations.
It should also be in accordance with any relevant requirements
of the local authority and fire authority and the relevant
recommendations of the following documents.
OFTEC Technical Boo Three: Installation requirements for
oil fired equipment.
OFTEC Easy Guides to non domestic oil feed pipes and oil
storage.

A
A
1.0m
1.0m YX
where:
X = 1.0m & Y = 0.5m or
X = 0.5m & Y = 1.0m
Fig 1 Minimum clearance distances
10
4. Installation of Air Heater(s)
4.1 General
Before installation, chec that the local distribution conditions,
fuel specification, and adjustment of the appliance (see data
plate) are compatible.
Important:
Copper Sulphide / Black Dust
In some areas of the UK, particularly Northern Ireland, problems
have been experienced with copper sulphide (more commonly
referred to as Blac Dust) forming on the inner surfaces of
copper gas supply pipewor . This dust can enter the gas stream
and may lead to bloc ages of valves, filters and injectors.
If this heater is being installed in an area where Blac Dust
is nown to be a problem, and copper gas supply pipewor is
used, it is recommended that a filter having a stainless steel 50
micron mesh and suitable for Natural Gas is fitted at the inlet
to the appliance immediately downstream of the main appliance
isolation valve. The end user should be advised that the filter
will require periodic cleaning or replacement at least once per
year, during the annual service, or more often if the problem is
severe.
4.2 Location
The location chosen for the air heater must permit:
- the provision of a satisfactory flue system and an adequate
air supply.
- adequate space for servicing and air circulation around the
air heater.
The heater(s) must not be installed in conditions for which it
is not specifically designed e.g. where the atmosphere is corrosive
or salty, and they are not suitable for outdoor use unless the
CP/EA style is specified. CP/EA heaters must be installed on
a plinth such that there is a minimum distance of 0.5m between
ground level and the lowest point of any air inlet grilles.
Where the location of the air heater is such that it might suffer
external mechanical damage e.g. from overhead cranes, for
lift truc s, it must be suitably protected.
CP heaters are for normal operation within an ambient
temperature range of -10 to 25°C.
The air heater must be installed in accordance with the rules in
force and the relevant requirements of any fire regulations or
insurance company's requirements appertaining to the area in
which the heater is located, particularly where special ris s are
involved such as areas where petrol vehicles are housed, where
cellulose spraying is carried out, in wood wor ing departments
etc.
IMPO TANT:
Heaters shall not be installed in:-
a) Those parts of spaces within buildings that have been
classified as hazardous areas as defined in
BS 5345 : Part 2.
b) Where there is a foreseeable ris of flammable particles
or gases or corrosion inducing gases or vapours being
drawn into either the heated air stream or the air for
combustion. In such cases installation may only proceed
if the air to be heated is ducted to the heater from an
uncontaminated source, preferably from outside the
building. The option of ta ing combustion air from the
space is not permitted. In certain situations where only
airborne particles are present it may suffice to fit filters
on the main air inlet duct of the heater. Advice in these
instances may be obtained from Powrmatic Ltd.
c) In areas subjected to significant negative pressures due to
extract systems.
4.3 Installing the Air Heater
If necessary consideration should be given to mounting the
heater on resilient pads, or equivalent, to minimise transfer of
noise and vibration to the structure of the building.
Floor mounted heaters must be installed on a level
noncombustible surface.
Heaters mounted at high level must be supported on a purpose
designed platform or framewor that is suspended from vertical
drop rods, chains or straps or mounted on specifically designed
cantilever brac ets from a non-combustible wall. The method
of installation support must be capable of adequately supporting
the weight of the unit (See Table 2, Page ?) and any ancillary
equipment. Before installing the heater the existing structure
must be inspected to ensure it is suitable. All supports should
be protected against the effects of rust or corrosion.
Whichever method of mounting the air heater is used the
following minimum clearances for installation and servicing
must be observed.
To the front The depth of the heater
To the rear 1.0m
To at least one side 1.0m
On the opposite side 0.5m
Above the heater 1.0m
Any combustible material adjacent to the air heater and the flue
system must be so placed or shielded as to ensure that its
temperature does not exceed 65 °C.
If the method of mounting allows for any movement of the
heater it is essential that all gas, duct, and electrical connections
to the heater are made with flexible connections to maintain
continuity of connection.
4.4 Combustion Air Supply
In buildings having a design air change rate of less than 0.5/h,
and where heaters are to be installed in heated spaces having
a volume less than 4.7 m³/ W of total rated heat input grilles
shall be provided at low level as follows:-
(1) for heaters of heat input less than 60 W, the total minimum
free area shall not be less than 4.5 cm² per ilowatt of
rated heat input.
(2) for heaters of heat input 60 W or more, the total minimum
free area shall not be less than 270cm² plus 2.25 cm² per
ilowatt in excess of 60 W rated heat input.
Where the air heater(s) are to be installed in a plant room the
plant room must have permanent air vents communicating
directly with the outside air, at high level and at low level.
Where only high level air vents are available, ducting down to
floor level for the lower vents should be used.
All air vents should have negligible resistance and must not be
sited in any position where they are li ely to be easily bloc ed
or flooded or in any position adjacent to an extraction system
which is carrying flammable vapour.
Grilles or louvres should be so designed that high velocity air
streams do not occur within the plant room.
The basic minimum effective area requirements of the air vents
are as follows:
(a) Low Level (inlet)
(1) for heaters of total rated heat input less than 60 W:
9cm² per ilowatt of rated heat input.
(2) for heaters of total rated heat input 60 W or more:

11
540 cm² plus 4.5 cm² per ilowatt in excess of
60 W total rated input.
(b) High Level (outlet)
(1) for heaters of total rated heat input less than
60 W: 4.5cm² per ilowatt of rated heat input.
(2) for heaters of total rated heat input 60 W or more:
270 cm² plus 2.25 cm² per ilowatt excess of 60 W
total rated input.
4.5 Flue System
A single wall tee piece is supplied with each heater and must
be fitted to the flue outlet soc et on the heater. A closed chimney
system that conforms to the requirements of
EN1856-1 and has a designation appropriate to the application
must be connected to the outlet of this tee. The cross sectional
area of the chimney serving the appliance must be not less than
the area of the flue outlet of the air heater. The chimney must
have a minimum height, from the heater to the flue terminal,
of 2m. Horizontal runs of flue are not permitted.
If necessary a single offset using two 45° bends can be included
to avoid obstructions. The maximum equivalent resistance of
the flue system must not exceed 20 pa. Details of how to
calculate the resistance of the flue to be installed are given in
Appendix A.
In order to minimise condensation the use of twin wall chimney
is recommended. Where condensation in the chimney is
unavoidable provision should be made for condensation to flow
freely to a point at which it can be released, preferably into a
gully. The condensation pipe from the chimney to the disposal
point should be of non-corrodible material of not less than
22mm (3/4") size.
Facilities should be made for disconnecting the chimney pipe(s)
from the air heater(s) for inspection and servicing purposes.
It is recommended that consideration be given to the fitting of
a terminal at the chimney flue outlet, however, where the heater
flue is less than 200mm (8") in diameter an approved terminal
must be fitted.
The chimney must terminate in a freely exposed position and
must be situated so as to prevent the products of combustion
entering any opening in a building in such concentration as to
be prejudicial to health or a nuisance..
The chimney must be supported independently of the air heater.
A chimney support brac et that fits directly to the rear of the
heater is available as an optional extra. The chimney terminal
must not be installed so as to be less than:
- 300mm below an opening e.g. window, air bric etc.
- 200mm below eaves or gutter.
- 300mm from an internal or external corner.
- 1200mm from a surface facing the terminal.
- 1500mm vertically from another terminal on the same wall.
- 300mm horizontally from another terminal on the same wall.
- 2000mm from ground level.
4.6 Fuel Connection
4.6.1 Gas Connection (if applicable)
A servicing valve and union must be fitted at the gas inlet to
the heater to facilitate servicing. The gas supply to the air heater
must be completed in solid pipe wor and be adequately
supported. Heaters suspended by drop rods, straps or chains
must have a flexible connection as the final lin between the
gas supply pipe wor and the heater. Sufficient slac must be
left in the connection to ta e account of normal movement of
the heater.
Warning:
When completing the final gas connection to the heater do not
place undue strain on the gas pipe wor of the heater.
4.6.2 Oil Connection (if applicable)
Refer to the supplied burner installation instructions for details
regarding oil supply options.
4.7 Electrical Connections
Wiring external to the air heater must be installed in accordance
with the I.E.E. Regulations for Electrical Installations and any
local regulations which apply. Wiring should be completed in
flexible conduit.
Heaters are for use with 230V, 1N, 50Hz or 400V, 3N, 50Hz
supplies (see eater data plate).
The method of connection to the main electricity supply must:-
- facilitate the complete electrical isolation of the heater(s) that
will prevent remote activation of the heater during servicing.
- be in a readily accessible position adjacent to the heater(s).
- serve only the heater(s).
- have a contact separation of at least 3mm in all poles. See the
accompanying wiring diagram for the heater electrical
connections.
All units are fully prewired and only require final connections
for the incoming mains supply. Heaters not supplied with inbuilt
time and temperature controls will also require completion of
the external control circuit (230V) via a room thermostat, time
cloc etc. and, if applicable, the remote low level loc out reset.
All heaters must be earthed.
Reference must be made to Table 3 (Page 7) to ascertain the
electrical loading of the unit(s) being installed so that cables of
adequate cross-sectional area are used for the electrical
installation. The length of the conductors between the cord
anchorage and the terminals must be such that the current
carrying conductors become taut before the earth conductor if
the cable or cord slips out of the cord anchorage. All external
controls must be of an approved type.
Heaters supplied less main fan must be electrically interloc ed
to the air movement system so that this is started in the same
manner as the air heater fan would be viz. A connection from
the appropriate heater terminal (see wiring diagram wit t e
eater) must be made to one side of the fan motor contactor
coil, the other side of the coil being connected to Neutral. Under
no circumstances must the fan motor electrical supply be ta en
direct from the internal wiring of the heater.
4.8 Air Distribution System
For free-blowing units used in buildings having a low heat loss
i.e. where single units are required to cover a large floor area,
and in buildings with high roof or ceiling heights Calecon
thermal economiser units should be fitted to ensure even heat
distribution and minimise stratification.
Care should be ta en to avoid impeding the heater air throw
with rac ing, partitions, plant or machinery etc. Various outlet
configurations are available as optional extras to modify the air
throw pattern to suit particular site conditions.
CP-G *D models are designed for use with duct wor to more
precisely define the point of air delivery, and /or provide ducted
return air or ducted fresh air inlet. All ducting must be
independently supported of the air heater.
All delivery and return air ducts, including air filters, jointing
and any insulation or lining must be constructed entirely of
materials which will not contribute to a fire, are of adequate
strength and dimensionally stable for the maximum internal
and external temperatures to which they are to be exposed
during commissioning and normal operation.
Where inter-joist spaces are used as duct routes they should be
suitably lined with a fire-resisting material.
A full and unobstructed return air path to the air heater(s) must
be provided.
If the air heater(s) is installed in a plant room the return air
inta e(s) and the warm air outlet(s) from the heater(s) must be
fully ducted, into and out of the plant room to avoid interference
with the operation of the heater from other equipment.
The openings in the structure of the plant room through which
the ducting passes must be fire stopped.
Care must be ta en to ensure that return-air inta es are ept
clear of sources of smells and fumes, and where there is any
possibility of pollution of the air by dust, shavings etc.,
precautions must be ta en to prevent contamination.

12
If necessary suitable barrier rails should be provided to prevent
any combustible material being placed within 900mm of the
outlets.
Joints and seams of supply ducts and fittings must be securely
fastened and made airtight.
It is recommended that ducting should be connected to the
heater spigots via an airtight flexible coupling of noncombustible
material. Before fitting coupling it must be ensured that a
maximum clearance of 13mm will be maintained between the
ends of the ducting and the heater spigots.
If required sound attenuators may be fitted in inlet and outlet
ducts to reduce airborne fan noise. Materials used in outlet
sound attenuators must be capable of withstanding 100 °C air
temperature without any deterioration.
4.9 Room Thermostat Siting
If a remote room thermostat is used it should be fitted at a point
which will be generally representative of the heated area as far
as temperature is concerned. Draughty areas, areas subjected
to direct heat e.g. from the sun, and areas where the air movement
is relatively stagnant e.g. in recesses, are all positions to be
avoided for siting the thermostat.
The thermostat should be mounted about 1.5m (5ft) from floor
level.
Any room thermostat, frost thermostat, time cloc etc. must be
suitable for switching 230V, 5A and must be of the 'snap action'
type to minimise contact bounce.
For electrical connections of external controls see t e
accompanying wiring diagram.

1. Remove the sealing screw from the pressure test point located
on the side of the gas inlet to the burner head and attach a
pressure gauge. Remove the sample point cover plug from the
outlet flue length and insert a CO2 measuring instrument.
2. Turn ON the main electricity supply and chec that the
following sequence of events occur.
i) Burner fan runs.
ii) Ignition spar is heard.
iii) Main gas valves open and main gas flame is established.
3. Chec that the main burner gas pressure agrees with that
stated on the heater data plate. If necessary adjust the main
burner gas pressure (Fig 2) by rotating the adjustment screw
under the cover flap. If the range of adjustment does not allow
for setting of the correct burner pressure the main volume
regulator may also be used. It is recommended that the main
governor adjustment is within 50% to 75% of its range.
4. Measure the CO2 content of the flue gases. If necessary adjust
the combustion air damper of the burner (Refer to t e Burner
Instructions) to obtain a reading of 9.0 - 9.5%
5. Turn OFF the burner, remove pressure gauge and refit sealing
screw in pressure test point and flue sample point cover plug.
5.4.1.3.2 C -G 400 - 2000
1. Remove the sealing screw from the pressure test point located
on the side of the gas inlet to the burner head and attach a
pressure gauge. Remove the sample point cover plug from the
outlet flue length and insert a CO2 measuring instrument.
2. Turn ON the main electrical supply and the burner will run
through its sequence until main flame is established. Chec that
the main burner gas pressure agrees with that stated on the
heater data plate. If necessary adjust the main burner gas pressure
(Fig 2) by rotating the adjustment screw under the cover flap.
If the range of adjustment does not allow for setting of the
correct burner pressure the main volume regulator may also be
used. It is recommended that the main governor adjustment is
within 50% to 75% of its range.
3. Measure the CO2 content of the flue gases. If necessary adjust
the combustion air damper of the burner (Refer to t e Burner
Supplement) to obtain a reading of 9.0 - 9.5%.
4. Turn OFF the burner. Remove pressure gauge, refit sealing
screw in pressure test point and flue sample point cover plug.
5.4.1.4 Final Soundness Test
1. After ma ing final gas rate chec s all joints on the gas controls
assembly must be tested for soundness using lea detection
fluid.
5.4.1.5 Flame Safeguard
1. Whilst the burner is in operation close the gas service valve.
The burner should go to loc out within 1 second.
5.4.1.6 Gas Burner Max. Air ressure Switch ( 2)
Note: Refer to the burner instruction boo let but follow the
steps below.
5. Commissioning & Testing
5.1 Electrical Installation
Chec s to ensure electrical safety must be completed by a
competent person.
5.2 Gas Installation (if applicable)
The whole of the gas installation, including the meter, should
be inspected and tested for soundness and purged in accordance
with the recommendations of IGE/UP/1 or IGE/UP1A or
IGE/UP/1B as appropriate.
5.2 Oil Installation (if applicable)
The whole of the oil installation, including the tan , should be
inspected and tested in accordance with the recommendations
of OFTEC.
5.3 Air Distribution System
The system should be chec ed to ensure that the installation
wor has been carried out in accordance with the design
requirements.
Particular attention should be given to the correct arrangement
of delivery ducts and registers, return air ducts and grills and
general adequacy of return air paths.
For CP /*D heaters ensure that the total duct system resistance
does not exceed the available air pressure of the equipment
supplied refer to Table 2 (Page 7). If the duct system resistance
is less than the available air pressure of the equipment supplied
additional resistance must be introduced e.g. by adjustment of
duct outlet nozzles and balancing of the duct system. Conversely
if the duct system resistance is greater than the available air
pressure of the heater supplied the system resistance must be
reduced.
5.4 Lighting the Air Heater
5.4.1 Gas Fired Heaters
Note: Refer also to the burner instruction boo let supplied with
the heater. This provides information on adjusting the burner,
setting up the air pressure switches, system chec s and fault
finding detail.
5.4.1.1 Gas Controls Assembly - Soundness Check
1. Ensure the gas service valve at the inlet to the gas controls
assembly is shut.
2. To prove soundness of the first main safety shut-off valve:-
a) Connect pressure gauge to the inlet pressure test point
on the main valve bloc or inlet pipewor .
b) Open gas service valve and allow pressure to stabilise
before shutting it again. The valves are sound if no pressure
drop is observed. If a pressure drop is observed do not
proceed until the fault has been rectified. Remove pressure
gauge and refit sealing screw in pressure test point.
5.4.1.2 Sequence Check
1. Ensure that the gas service valve is closed and that the main
electrical supply to the heater is switched off.
2. Start the burner by setting the time cloc and thermostat to
call for heat or complete the external control circuit.
3. Turn ON the main electrical supply and chec that the
following sequence of events occurs.
i) Burner fan runs
ii) Ignition spar is heard
iii) Start gas valves open (Main gas valves on CP-G100 - 300.
iv) Burner goes to loc out as there is no gas supply.
4. Switch OFF main electricity supply.
5.4.1.3 Final Adjustment
5.4.1.3.1 C -G 100 - 300
ressure adjustment screw
under cover
Main volume regulator
13
Fig 2 Dungs Valves
pressure adjustment

1. The max. air pressure switch must be set after all other
adjustments have been made.
2. Begin with the switch at its highest setting and the burner
wor ing at the correct input for high fire.
3. Slowly adjust the pressure switch dial anti-cloc wise, to
decrease the set point, until the burner loc s out. Immediately
stop adjustment.
4. Now increase the set point by 0.1mb and restart the burner.
5. If the burner fails to start, or shuts down due to the pressure
surge on ignition, increase the pressure switch setting by a
further 0.1mb and restart the burner.
6. Continue until the burner reliably starts.
5.4.2 Oil Fired Heaters
5.4.2.1 Initial burner startup
1.Chec that fuel is present in the tan and at the oil filter fitted
on the front of the heater.
2. Chec that fitted fire valves are open.
3. Refer to the burner instruction boo and fit a pressure gauge
(and vent valve if the burner is on a single pipe oil feed) to the
oil pump.
4. Set the time cloc and thermostat to call for heat or complete
the external control circuit.
5. Turn ON the main electrical supply and chec that the burner
fan starts.
6. Note: This step is only for when a vent valve is being used.
Open the vent valve. When air free oil issues from the vent
valve close the valve and the burner will fire when the ignition
spar is present. (Note: This procedure may need to be repeated
several times if the oil line cannot be purged of air within one
ignition cycle. At the end of the unsuccessful ignition cycle the
burner will go to loc out. Wait 2/3 minutes and then depress
the red reset button on the burner control box to restart the
ignition cycle.)
7. After completion of the pre-purge period the ignition spar
will be energised and the burner oil solenoid valve will open
and the burner will light.
Warning: If burner ignition cannot be achieved after 2-3 attempts
do not continue to recycle through the ignition sequence but
ascertain the cause and rectify.
WA NING:
If continued unsuccessful ignition attempts are made it is possible
to accumulate a significant quantity of oil and oil mist in the
combustion chamber which, if the burner then fires, can result
in a dangerous situation. Any such accumulation of oil must be
removed by safe means before any further attempt to light the
burner.
5.4.2.2 Final Adjustment
1.Remove the sample point cover plug from the outlet flue
length and insert a CO2 measuring instrument.
2. Relight the burner. Chec that the pump pressure is as specified
on heater data plate. If adjustment of the pump pressure is
necessary refer to the burner instructions and complete.
3. Measure the CO2 content of the flue gases. If necessary adjust
the combustion air damper of the burner (Refer to t e Burner
Instructions) to obtain a reading of 11.5 - 13.0%.
8. Turn OFF the burner. Remove pressure gauge and refit sealing
plug, refit flue sample point cover plug.
5.4.2.3 Final Checks
1. After ma ing final adjustments chec that there are no lea s
on the oil pipewor .
5.5 Handing over the Air Heater
Hand these instructions to the user or purchaser for retention
and instruct the User in the efficient and safe operation of the
air heater.
In the event that the premises are not yet occupied turn off the
gas and electricity supplies and leave instructional literature
with the heater.
14

15
Fig 3 Fan belt
tension setting
6. Servicing
WARNING: Always switch off and disconnect electricity supply,
close the gas service valve or turn off the oil supply before
carrying out any servicing wor or replacement of failed
components.
6.1 General
Full maintenance should be underta en not less than once per
year. After any servicing wor has been complete or any
component replaced the air heater(s) must be fully commissioned
and tested for fuel tightness as described in Section 5.
6.2 Burner Servicing/Maintenance
1. Refer to the burner instructions supplied with the heater and
complete the servicing/maintenance instructions therein.
Note: In the case of gas burners ignore any references in the
burner supplement to the gas controls assembly.
6.3 Heat Exchanger Cleaning
1. Remove the fan/limit thermostat(s) as described in 6.6.4 and
then remove the upper front panel of the heater to expose the
heat exchanger clean out panel. Remove the bolts securing the
panel, pull the panel forwards at the bottom and then lift up to
disengage from the heat exchanger and remove.
2. Withdraw the heat exchanger baffles.
3. Brush through heat exchanger tubes and remove loose material
using a vacuum cleaner.
4. If it is necessary to also gain access to the combustion chamber
disconnect the fuel and electrical connections from the burner.
Remove the nuts securing the burner to the heater and withdraw
the burner from the burner tube.
5. Reassemble all components in reverse order. Note: The
ceramic fibre gas et around the inside of the heat exchanger
clean out panel must be renewed. If the burner has been removed
the burner gas et should be replaced if necessary.
6.4 Fan Assembly
1. Remove the lower panels of the heater to gain access to the
fan section.
2. Inspect the fan blades to see that they are not damaged and
that there is no excessive build up of deposits that could give
rise to an imbalance. If necessary clean the fan blades using a
stiff brush and vacuum cleaner.
3. Replace panels accordingly.
6.5 Oil Filter (if applicable)
1. Release the securing bolt, or unscrew the filter bowl, to access
the filter.
2. Clean the filter or replace as deemed necessary.
3. Refit bowl ensuring that seals are correctly in place.
6.6 Replacement of Faulty Components
6.6.1 Burner Components
1. Refer to the burner instructions supplied with the heater for
information regarding replacement of components within the
burner.
6.6.2 Gas Controls Assembly (if applicable)
1. Remove the electrical connections from the gas control bloc .
2. Release the nuts securing the inlet and outlet flanges to the
gas control bloc and lift out the gas control bloc . Fit the
replacement assembly in reverse order ensuring the valve is
correctly orientated for the direction of gas flow.
6.6.3 Main Air Fan and Motor
Important: On 3ph heaters fitted with 3ph main fan motors
ensure that the fan direction of rotation corresponds with the
direction of rotation arrow on the fan guard or case. If necessary
reverse the direction of rotation by interchanging any two of
the motor live leads at the terminal strip in the electrical panel.
Should it be necessary to remove one or more of the fans for
cleaning proceed as follows.
6.6.3.1. C 100 - C 400
Note: These heaters are fitted with direct drive fan units.
1. Disconnect the fan motor electrical leads from the terminal
strip (Refer to wiring diagram supplied wit t e eater)
2. Remove the two screws, one on each side of the fan mounting
flange, that secure the fan to the fan shroud.
3. Remove the screws securing the heat exchanger mounting
frame to the fan shroud on the side that the fan is going to be
withdrawn.
4. Withdraw the fan from the slide rails.
5. Reassemble in reverse order.
6.6.3.2. C 500 - C 2000
Note: These units are fitted with belt driven main air fans.
1.Remove the lower side panels.
2. Release the motor mounting plate securing screws and then
remove the belt tension by turning the tension adjustment screw
anticloc wise. Remove the fan belts.
3. Remove the screws securing the fan mounting feet to the
heater framewor and remove the fan. It may be necessary to
re-orientate the fan within the fan compartment and also to
release the fan shroud fixings in order to pass the fan through
the heater frame. On units with twin or triple fan sets on a
common fan shaft it will be necessary to first remove the fan
shaft.
4. Inspect the fan belts and if necessary replace with new.
5. Replace components in reverse order.
6. Do not over tension the fan belts. There should be
approximately 15mm of deflection when downward pressure
is applied to the belt(s) halfway between the motor and fan
pulleys.
12mm - 15mm
6.6.4 Fan and Limit Thermostats
6.6.4.1 C 100 - C 1000 - Fan / Limit Thermostat
- Honeywell L4064N
1. Release the single screw securing the fan and limit thermostat
cover and remove cover by pulling forward.
2. Release wiring from clamp terminals by pushing a small
screwdriver into the clamp release holes adjacent to the clamps.
3. Remove the 2 screws securing the thermostat to the heater
panel and withdraw thermostat.
4. Reassemble new unit in reverse order referring to the heater
wiring diagram to ensure correct wiring location.
Important: A replacement fan/limit thermostat will have a
brass lin between the bottom fan terminal and the bottom limit
terminal (situated in the slot between the two terminals). This
MUST be removed, by brea ing the lin off using a pair of thin
nose pliers, before the replacement thermostat is installed.
5. Ensure that the fan and limit settings are as follows:-
Fan ON - 50°C, Fan OFF - 30°C
Limit CP 100 - 150 90°C
CP 200 - 800, 1000 110°C
CP 300 - 700 100°C

16
Fig 4 T ermostat Fan / Limit - Honeywell L4064N
CAUTION
DO NOT ROTATE - HOLD
DIAL WHEN SETTING POINTERS
2
0
4
0
6
0
8
0
1
0
0
1
2
0
F
A
N
L
I
M
I
T
O
F
F
O
N
O
F
F
C
°
Limit Setpoint
Adjustment
Fan Circuit
Limit Circuit
Limit Reset
Fan ON
Override
Set oint Dial
Jumper Location
Mechanical Limiter
Release oint
Mechanical limiter
Fan OFF Setpoint
Adjustment
Limit CircuitFan Circuit
Fan ON Setpoint
Adjustment
Note: The new L4064N may be supplied with the limit
temperature mechanically limited to less than the setting required.
To release the mechanical limit push a pointed object into the
small hole at the top of the dial. At the same time prevent the
dial from rotating and push the limit temperature adjuster around
to the required setting.

17
Dungs MB-DLE 403 B01 0.5 100 & 150 141378701
Dungs MB-DLE 405 B01 0.75 200 & 300 141378702
Dungs MB-DLE 405 B07 0.75 400 141378703
Dungs MB-DLE 407 B07 0.75 500 141378704
Dungs MB-DLE 410 B07 1.25 600 & 700 141378705
Dungs MB-DLE 412 B07 1.5 800 - 1250 141378706
Thermostat - Fan / Limit - Honeywell L4064N 100 - 700 143000303
Contactor - Danfoss CI 9 All 143000608
Overload - Danfoss TI 16 (0.6 - 0.92A) 100(3ph) 143056103
Overload - Danfoss TI 16 (1.2 - 1.9A) 150(3ph), 200(3ph) 143000861
Overload - Danfoss TI 16 (2.7 - 4.2A) 300 (3ph), 400 143000706
Overload - Danfoss TI 16 (4.0 - 6.0A) 500 - 800 143000707
Overload - Danfoss TI 16 (8.0 - 12.0A) 1000 143000770
Overload - Danfoss TI 16 (11.0 - 16.0A) 1250 143000850
Danfoss MCI 15 soft start 1000LHP, 1250, 143000620
1500 (x2),1500LHP (x2)
Danfoss MCI 25 soft start CP2000 (x2), CP2000LHP (x2) 143000621
Heat Exchanger Cleanout Door Gas et. All 170246006
Burner Gas et - Riello GS5. 100 141937080
Burner Gas et - Riello GS10. 150 - 300 141930806
Burner Gas et - Riello GS20. 400 - 600 142931252
Burner Gas et - Riello Gas 3 700 - 1000 142931240
Action
1. Chec electrical supply is ON.
2. Chec controls are ON or calling for heat.
3. Faulty burner control unit.
4. Limit thermostat open cicuit/faulty
1. Chec fuel supply is present.
1. Unit goes out on high limit -
a. Chec fan thermostat setting - See Section 6.6.4
b. Faulty fan thermostat - change
c.Chec limit thermostat setting - See Section 6.6.4
d. Faulty limit thermostat - change.
e. Faulty fan assembly - change.
f. Fan motor out on thermal overload. - Chec running amps.
See Table 3.- chec duct resistance See Table 2.
g. Chec that airflow through the heater is not resricted.
1. Chec continuity of fuel supply.
1. Summer/Winter switch set to Summer.
2. Fan thermostat set too low - chec setting See Section 6.6.4
3. Faulty fan thermostat - change
1. Fan motor or capacitor failed - replace.
2. Fan thermostat faulty - replace.
3. Fan contactor failed - replace (3ph units)
9. Fault Finding
Refer also to the burner supplement supplied with the heater
Fault
Main burner will not light
Main burner lights, but goes out before
main fan comes on or whilst controls still
calling for heat.
Main fan runs continuously
Main fan fails to run
Cause
Electrical
Gas/Oil
Electrical
Gas/Oil
Electrical
Electrical
9. Short List of arts
Refer also to the burner supplement supplied with the heater

18
Appendix A
Calculation Of Flue System Equivalent Resistance
The pressure resistance of the flue system (Pr) can be calculated from
Pr = 1.5 * [(PFF*H/D+SRF)Qm/Wm2]
Where Pr = Pressure resistance of the flue system in pa
PRF = Pipe Friction Factor
H = Effective flue height in m
D = Internal Diameter of flue in m
SRF = Sum of individual resistance factors
Qm= Mean Density of the column of exhaust gas in g/m3
Wm = Mean exhaust gas velocity in m/s
P F
Can be calculated from
PRF = 0.118*(0.21147/D0.4)
Where D = Internal Diameter of flue in m
S F
Typical resistance factors for individual components are as follows
Segmented 90° bend 0.5
45° Elbow 0.4
Cowl 1.0
Qm
Qm = 97000/(300*Tm)
Where the mean temperature of the column of exhaust gas (Tm) can be calculated from
Tm = 288+((Te-TL)/0.2)*(0.18)
Where Te is the exhaust gas temperature in °C
TL is the external air temperature in °C
Wm
Wm = M/(A*Qm)
Where A is the cross sectional area of the flue in m2
M is the exhaust gas mass flow in g/s which is as follows for the various units
CP 100 0.018 CP 500 0.125 CP 1500 0.3
CP 150 0.027 CP 600 0.14 CP 2000 0.4
CP 200 0.035 CP 700 0.145
CP 300 0.050 CP 800 0.16
CP 400 0.080 CP 1000 0.2