Powrmatic TE Series User guide

Installation and Servicing
Instructions
WARNING: THIS APPLIANCE MUST BE EARTHED
CE
£2.50 When supplied separately.
TE Range Issue 3 March 2000
The TE Range

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CONTENTS
Section Title Page
1. Introduction 2
2. Technical Data 3
3. General Requirements 4
4. Installation 5
5. Control Thermostat Siting 5
6. Commissioning & Testing 6
7. Servicing 6
8. Fault Finding 8
9. Short List of Parts 8
Tables Title Page
1. Dimensions (S.I. Units) 3
Figure Title Page
1. Belt Tension Adjustment 7
2. White Rodgers 5F464 7
Appendix Title Page
ACalculation of Flue System Equivalent 9
Resistance

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1. INTRODUCTION
ThePowrmaticTErangeofgasfiredforceddraught,closed
flue,fannedcirculationairheaterscoveraheatoutputrange
of220kW(75000Btu/h)to806kW(2750000Btu/h)andare
intended primarily for heating commercial or industry
premises.TheyarecertifiedforuseonNaturalGas,Group
H - G20.
Theheatersareforfloormounting,freeblowingapplications
only.
TE heaters have a double axial fan assembly fitted
upstream of the combustion chamber / heat exchanger
assembly to circulate the air being heated.
Heatersarefittedasstandardwithfullyautomaticmonoblock
forced draught gas burners and monoblock gas control
assemblies and are available with either High/Low or
modulatingburners.
Eachairheatermustbeconnectedtoa closedflue system
only.
Gas Safety (Installation & Use) Regulations 1994
It is law that all gas appliances are installed, adjusted and,
if necessary, converted by qualified persons* in accord-
ance with the above regulations. Failure to install appli-
ances correctly can lead to prosecution. It is in your own
interests and that of safety to ensure that the law is
complied with.
* e.g. Corgi Registered

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2TechnicalData
2.1 Dimensions
Specifications, Burner Pressures and Electrical Data.
TEheatersaredesignedtosuitindividualapplications.Pleaserefertotheenclosedspecificationsheetforthedataspecific
to the heater supplied.
Table 1. Dimensions (S.I. Units)
Model A B C D EFG
TE41 mm 1518 2991 1213 1975 1899 959 300/350
TE61 mm 2026 4058 1721 2534 2432 1365

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3. General Requirements
3.1 Related Documents
The installation of the air heater(s) must be in accordance
withtherulesinforceandtherelevantrequirementsofthe
Gas Safety Regulations, Building Regulations and the
I.E.E. Regulations for Electrical Installations.
It should be in accordance also with any relevant
requirementsofthelocalgasregion,localauthorityandfire
authorityandtherelevantrecommendationsofthefollowing
documents.
BritishGasPlcPublications
IM/11:1989FluesforCommercialandIndustrialGasFired
Boilers and Air Heaters
IM/16 : 1988 Guidance notes for the installation of gas
pipework, boosters and compressors in Customer’s
premises (excluding domestic installation of 25mm and
below).
BritishStandardsCodeof Practice
BS6230:1991InstallationofGasFiredForcedConvection
AirHeatersforCommercial and Industrial Space Heating.
3.2 Location
The location chosen for the air heater must permit the
provisionof asatisfactoryfluesystem andanadequate air
supply.Thelocationmustalsoprovideadequatespacefor
servicing and air circulation around the air heater.
The heater(s) must not be installed in conditions for which
itis notspecificallydesigned e.g.wherethe atmosphereis
corrosive or salty and where high wind speeds may affect
burneroperation,andtheyarenotsuitableforoutdooruse.
Where the location of the air heater is such that it might
suffer external mechanical damage e.g. from overhead
cranes, fork lift trucks, it must be suitably protected.
TE units are designed to operate in a maximum ambient
temperatureof25°C.
3.3 Gas Supply
3.3.1 Service Pipes
The local gas undertaking should be consulted at the
installationplanningstageinordertoestablishtheavailability
ofanadequatesupplyofgas.Anexistingservicepipemust
not be used without prior consultation with the local gas
undertaking.
3.3.2 Meters
A gas meter is connected to the service pipe by the local
gas undertaking or a local gas undertaking contractor. An
existing meter should be checked, preferably by the gas
undertaking, to ensure that the meter is adequate to deal
with the total rate of gas supply required.
3.3.3.InstallationPipes
Installation pipes should be fitted in accordance with
IM/16:1988.Pipeworkfromthemetertotheairheatermust
beofadequatesize.Donotusepipesofasmallersizethan
the inlet gas connection of the heater. The complete
installation must be tested for soundness as described in
the above Code. The complete installation must be tested
for soundness as described in BS 6230.
3.3.4.BoostedSupplies
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 undertaking must be
consulted before a gas pressure booster is fitted.
3.4 Flue System
Detailed recommendations for fluing are given in BS 5440,
Part 1 (Flues) and IM/11.
The air heater must be connected to a closed flue system.
The cross sectional area of the flue serving the appliance
must be not less than the area of the flue outlet to the air
heater.
Materialsusedfor the fluesystemshouldbe mechanically
robust, resistant to internal and external corrosion,
noncombustibleanddurableundertheconditionstowhich
they are likely to be subjected.
Prevention of condensation within the flue should be an
importantfactorinthedesignofthefluesystem.Inorderto
minimise condensation the use of double walled flue pipe
or insulation is recommended. If double walled flue pipe is
used it should be of an acceptable type.
Where condensation in the flue is unavoidable provision
shouldbemadeforcondensationtoflowfreelytoapointat
which it can be released, preferably into a gully. The
condensationpipefromthefluetothedisposalpointshould
be of non-corrodible material of not less than 22mm (1/2")
size.
Facilitiesshouldbemadefordisconnectingthefluepipe(s)
fromtheairheater(s)forinspectionandservicingpurposes.
The flue should terminate in a freely exposed position and
mustbesosituatedastopreventtheproductsofcombustion
enteringanyopeninginabuildinginsuchconcentrationas
to be prejudicial to health or a nuisance.
An approved terminal must be fitted at the flue outlet.
3.5 Air Supply
In buildings having a design air change rate of less than
0.5 /h, and where TE heaters are to be installed in heated
spaceshavingavolume less than 4.7 m3/kWoftotalrated
heat input grilles shall be provide at low level as follows:-
Thetotalminimum free area shall notbelessthan 270cm2
plus 2.25 cm2per kilowatt in excess of 60 kW rated heat
input.
Theairvent(s)shouldhavenegligibleresistanceandmust
not be sited in any position where it is likely to be easily
blocked or flooded or in any position adjacent to an
extraction system which is carrying flammable vapour.
3.6 Air Distribution System
Care should be taken to avoid impeding the air throw with
racking, partitions, plant or machinery etc.
A full and unobstructed return air path to the air heater(s)
mustbeprovided.
Care must be taken to ensure that return-air intakes are
kept clear of sources of smells and fumes, and in special
circumstanceswherethere is any possibilityofpollutionof
the air by dust, shavings etc., precautions must be taken

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by carefully positioning return air intakes and by the
provisionofscreenstopreventcontamination.
3.7 Electrical Supply
Wiring external to the air heater must be installed in
accordance with the I.E.E. Regulations for Electrical
Installationsandany local regulations which apply. Wiring
should be completed in flexible conduit.
TEheatersrequirea400V-3N,50Hzsupply.The method
of connection to the main electricity supply must facilitate
thecompleteelectricalisolationoftheairheater(s)andthe
supply should serve only the air heater(s).
Theisolatormusthaveacontactseparationofatleast3mm
in all poles. The method of connection should be provided
adjacenttotheairheater(s)inareadilyaccessibleposition.
See the accompanying wiring diagram for the heater
electrical connections.
4. Installation of Air Heater(s)
4.1General
Before installation, check that the local distribution
conditions, nature of gas and pressure, and adjust-
ment of the appliance are compatible.
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,
particularlywherespecialrisksareinvolvedsuchasareas
wherepetrolvehiclesarehoused,wherecellulosespraying
is carried out, in wood working departments etc.
Whichever method of mounting the air heater is used the
followingminimumclearancesforinstallationandservicing
mustbeobserved.
Tothe front 1.0m
To the rear The depth of the heater
To the side 1.0m
Abovetheheater 1.0m
Anycombustiblematerialadjacenttotheairheaterandthe
fluesystemmustbesoplacedorshieldedastoensurethat
its temperature does not exceed 65 °C.
IMPORTANT:
1.Noairheatershallbeinstalledwherethereisaforeseeable
risk of flammable particles, gases vapours or corrosion
inducing gases or vapours being drawn into either the
heated air stream or the air for combustion. In such cases
installationmayonlyproceediftheairtobeheatedandthe
air for combustion are ducted to the heater from an
uncontaminatedsourcepreferablyoutsidethe building. In
certainsituationswhereonlyairborneparticlesarepresent
itmay suffice to fit filters on the air inletducts of the heater.
AdviceintheseinstancesmaybeobtainedfromPowrmatic
Ltd.
4.2Installation
TEheaterinstallationmayonlybecompletedbyPowrmatic
Ltdor their appointedrepresentatives.
The heaters must be installed on a level noncombustible
floor capable of supporting the weight of the heater.
4.3 Flue System
ATeepieceissuppliedwitheachheaterandmustbefitted
totheflueoutletsocketontheheater.Thefluesystemthen
connects directly on to the tee. For flue sizes refer to Data
Sheet.Allunitsmustbefittedwitha fluehavingaminimum
height,fromtheheatertotheflueterminal,of2m.Horizontal
runs of flue are not permitted unless they are adequately
compensated by associated vertical sections.
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 30pa.
Details of how to calculate the resistance of the flue to be
installed are given in Appendix A.
4.4 Condensate Drainage
Thedesignofthefluesystemshouldminimisetheformation
of condensation, however when this is envisaged to be a
problemprovisionshouldbemadeforcondensationtoflow
to a joint where it can be drained, preferably into a gully.
4.5 Gas Connection
Aservicing valve and downstream union must be fitted at
theinlettotheairheatergascontrolsassemblytofacilitate
servicing. The gas supply to the air heater must be
completedinsolidpipeworkandbeadequatelysupported.
WARNING
Whencompletingthefinal gasconnectiontotheheater do
not place undue strain on the gas pipework of the heater.
4.6 Electrical Connections
Allunitsarefullypre-wiredandonlyrequirefinalconnections
for the incoming mains supply and, if required by the
specification, completion of any external control circuits
e.g. via a room thermostat, time clock etc. The electrical
supplymustbe run toapointadjacent to theheaterandbe
suitably terminated to provide an isolation point that will
prevent remote activation of the unit during servicing. The
heater electrical panel is located at the front of the heater
and cable entry points are provided in the adjacent heater
framework.Referencemustbemadetotheencloseddata
sheettoascertain theelectricalloadingof the airheater(s)
being installed so that cables of adequate cross-sectional
area to safely carry that load are used for the electrical
installation.Thelengthoftheconductorsbetweenthecord
anchorageandtheterminalsmustbesuchthatthecurrent
carryingconductorsbecometautbeforetheearthconductor
if the cable or cord slips out of the cord anchorage. All
external controls must be of an approved type.
See the wiring diagram accompanying these instructions.
5. Control Thermostat Siting
If the specification requires a remotely mounted control
thermostat it should be fitted at a point which will be
generally representative of the heated area as far as
temperatureisconcerned.Draughtyareas,areassubjected
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
the floor.
Any thermostat, time clock etc. must be suitable for
switching 230V, 5A and must be of the 'snap action' type

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to minimise contact bounce.
For electrical connections of external controls see the
wiringdiagram accompanying these instructions.
6. Commissioning & Testing
Note: Turn key for electical panel access door locks may
beusedtooperatedoorelctricalinterlockforcommissioning
purposes .
6.1 ElectricalInstallation
Checks to ensure electrical safety must be carried out by
aqualifiedperson.
6.2 GasInstallation
The whole of the gas installation, including the meter,
shouldbeinspectedandtestedforsoundnessandpurged
in accordance with the recommendations of IM/16:1988.
6.3 Fan Rotation
1. Open main electrical panel and switch Eurotrol contol
(see Eurotrol manual supplied) in main electrical panel to
(SUMMER) and the time clock to 'ON'.
1.Closemainelectricalpanelandwithdoorisolatorswitch
'ON'turn the AUTO-OFF-MAN switch to 'ON' tostart main
airfans. Ensurethatthefandirectionofrotationcorresponds
with the direction of rotation arrow on the fan shroud. If
necessaryreversethedirectionofrotationbyinterchanging
any two of the 3ph main supply leads at the terminal strip
in the electrical panel.
2.Reset the Eurotrol to (Winter)
6.4 Lighting the Air Heater
6.4.1 GasControlsAssembly-SoundnessCheck
1. Ensure the gas service valve at the inlet to the gas
controls assembly is shut.
2.Toprovesoundnessofthefirstmainsafetyshut-offvalve
and first start gas safety shut-off valve:-
a) Connect pressure gauge to the inlet pressure test
point on the main valve block or inlet pipework.
b) Opengasservicevalveandallowpressuretostabilise
before shutting it again. The valves are sound if no
pressure drop is observerved. If a pressure drop is
observed do not proceed until the fault has been
rectified.Remove pressuregaugeand refitsealing
screw in pressure test point.
6.4.2 SequenceCheck
1.Refertotheburnerinstructionssuppliedwiththeheater.
6.4.3 FinalAdjustment
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
plugfromtheoutlet fluelengthandinserta CO2measuring
instrument.
2. Remove the link in the main electrical control panel to
isolate the main gas valves.
3.Turn"ON"the main electricity supply and checkthatthe
followingsequenceof events occur.
i) Burnerfan runs.
ii) Ignition spark is heard.
iii) Startgas valves open.
iv) Start gas flame is established.
4. Check that the start gas pressure agrees with that in
Tables3.1or3.2.Ifnecessaryadjustthestartgaspressure
(See Data Sheet).
4. Turn "OFF" the main electricity supply.
5. Reconnect the main gas valves electrical link.
6. Turn "ON" the main electrical supply and the burner will
run through its sequence untill main flame is established.
Check that the main burner gas pressure agrees with that
on the specification sheet. If necessary adjust the main
burner gas pressure (See Data Sheet and also Burner
Manualformethod).
7. Measure the CO2content of the flue gases. If it is
necessary to adjust the combustion air ratio controls, to
obtain a reading of 9.0 - 9.5%, refer to the Burner Manual.
8.Removepressuregauge,refitsealingscrewinpressure
test point and flue sample point cover plug.
6.4.4FinalSoundnessTest
1. After making final gas rate checks all joints on the gas
controls assembly must be tested for soundness using
leak detection fluid.
6.4.5ControlSettings
1. The mode setting of the Eurotrol OSII should be
(Winter).
2.Themodulating control temperature setpointshouldbe
2-3°C lower than the Eurotrol OSII day set point.
6.5 Hand Over
Hand the Users Instructions to the user or purchaser for
retention and instruct in the efficient and safe operation of
the air heater and associated controls.
Adjust the automatic controls to those values required by
the User.
Finally, advise the user or purchaser that, for continued
efficientand safe operationoftheairheater, it is important
that servicing is carried out annually.
In the event that the premises are not yet occupied turn off
the gas and electricity supplies and leave instructional
literature adjacent to gas meter.
7. Servicing
WARNING: Always switch off and disconnect electricity
supply and close the gas service valve before carrying out
any servicing work or replacement of failed components.
AccessdoorsonTEunitsarefittedwithelectricalinterlocks
however these alone must not be relied upon to prevent
equipmentoperationduringmaintenaceorservicingwork.
7.1General
Fullmaintenanceshouldbeundertakennotlessthanonce
per year. After any servicing work has been completed or
any component replaced the air heater(s) must be fully
commissioned and tested for soundness as described in
Section 6.
7.2 Burner Maintenance
1.RefertotheBurnerSupplementsuppliedwiththeheater.

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7.3 Heat Exchanger Cleaning
1.Disconnectthegassupply attheinlettothegascontrols
assembly.
2. Unplug the electrical connections from the heater
electrical panel to the buner.
3. Remove the nuts securing the burner to the heat
exchangerandremovetheburner.
4.Removethefixingsof thesecondsection(fromthefloor)
rear panel and hinge panel down to expose the heat
exchanger clean out access plate.
5. Remove the nuts securing the plate and remove.
6. Withdraw the heat exchanger baffles, if fitted.
7. Brush through heat exchanger tubes and remove loose
material using a vacuum cleaner.
8.Reassembleallcomponentsinreverseorder.Inspectall
gaskets and replace if necessary.
7.4 Fan Assembly
1. Gain access to the fan section through the access door
at the front left hand side.
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. Inspect the fan drive belts and replace if necessary.
4.Lubricatethe fanshaftballracebearings using agrease
gun on the grease nipple of each bearing.
7.5 Replacement of Faulty Components
7.5.1.BurnerComponents
1.Refertotheburnersupplementsuppliedwiththeheater.
7.5.2 GasControlsAssembly
1.Refertotheburnersupplementsuppliedwiththeheater.
7.5.3MainFanMotors
1. Release the motor mounting plate securing bolts and
then release the belt tension by turning the tension
adjustment screw clockwise. Remove the fan belts.
2.Disconnect the electrical connections from the motor
andremovethemotor.Ifrequiredremovethemotorpulley
and fit same to the new motor.
3. Fit new motor and reassemble in reverse order.
4. Apply belt tension until a 12mm-15mm deflection is
obtained when the centre of the belt is firmly depressed.
See Figure below.
Fig1BeltTensionAdjustment
7.5.4MainAirFan(s)
Should it be necessary to replace one or both of the fans
proceed as follows.
1.Removeoneortwoheat exchangermodulesidepanels
closeto thefan(s)togain accesstothe top ofthefan shaft.
2.Preventfanshaftrotationwithaspanneronthefanshaft
flatsandreleasethelockingbolt(righthandthread)holding
the fan assembly onto the shaft. Lift of the fan.
3. Fit new fan(s) and reassemble in reverse order. Ensure
theloosekeythatpreventsthefanassemblyrotatingonthe
fan shaft is refitted.
7.5.4AirFanPullies
1.Release the motor mounting platesecuring screws and
thenrelease the belt tension byturning the tensionadjust-
ment screw clockwise. Remove the fan belts.
2.Preventfanshaftrotationwithaspanneronthefanshaft
flatsandreleasethelockingbolt(righthandthread)holding
the pulley onto the shaft and remove pulley.
3. Fit new pulley and reassemble in reverse order. Ensure
the loose key that prevents the pulley rotating on the fan
shaft is refitted.
7.5.5FanandLimitThermostats
7.5.5.1 Fan / Limit Thermostat - White Rodgers 5F464
Note: 2 fan/limit thermostatsare fitted.
1. Release the single screw securing the fan and limit
thermostatcoverandremovecoverby pullingforward.
2. Release wiring from screw terminals.
3.Removethetopsidepanelfromtheheatertogainaccess
totheheatexchangerand release the thermostat sensing
phial from its holder on top of the heat exchanger.
3. Remove the 2 screws securing the thermostat to the
heater panel and withdraw thermostat and phial.
4. Reassemble new unit in reverse order refering to the
heater wiring diagram to ensure correct wiring location.
5. Esure that the fan and limit settings are as follows:-
FanON 50°C
FanOFF 30°C
Limit 100°C
Fig2WhiteRodgers5F464
7.5.5.3 High Limit Thermostat.
1. Release the two screws securing the limit thermostat
Summer / Winter Switch
Limit Circuit Fan Circuit
Fan Settings
Limit Settings

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housingcoverandremovecoverbypullingforward.
2.Releasethethermostatfromthefrontcover,twoscrews
3. Pull off wiring connectors from under the thermostat.
4.Remove a central side panel from the heater exchanger
section to gain access to the heat exchanger and release
the thermostat sensing phial from its holder on top of the
heat exchanger and withdraw thermostat and phial.
5. Reassemble new unit in reverse order refering to the
heater wiring diagram to ensure correct wiring location.
6. Ensure that the setting is as follows:-
Limit 100°C
9. Short List of Parts
Refer to the burner supplement supplied with the heater and the enclosed short list of parts.
Refer to Powrmatic Ltd for the details of any parts not listed.
8. 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.
Main fan runs continuously
Main fan fails to run
Cause
Electrical
Electrical
Electrical
Electrical
Action
1. Check electrical and gas supplies are ON.
2. Check controls are ON or calling for heat.
1. Unit goes out on high limit -
a. Check fan thermostat setting - See Section 7.5.5.
b. Faulty fan thermostat - change
c. Check limit thermostat setting - See Section 7.5.5.
d. Faulty limit thermostat - change.
2. Faulty fan assembly - change.
3. Fan motor out on thermal overload. - Check running amps. See
specification sheet.
1. Summer/Winter switch set to Summer.
2. Faulty fan thermostat - change
1. Fan motor or capacitor failed - replace.
2. Fan thermostat faulty - replace.
3. Fan contactor failed - replace
4. Door interlock faulty

Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.
HEATING DIVISION
Winterhay Lane
Ilminster, Somerset TA19 9PQ
Tel: [phone] Fax: [phone]
BSI Registered Firm
FM 414
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