Powrmatic LX Series User, Installation & Servicing Manual
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Powrmatic LX Series User, Installation & Servicing Manual

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Doc Ref: M110 Issue 1.0 Dec 2020
®
User, Installation & Servicing Manual
Issue 1.0 Dec 2020
ErP COMPLIANT
J A N U A R Y 2 0 2 1
w w w . p o w r m a t i c . c o . u k

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  • Page 1 Doc Ref: M110 Issue 1.0 Dec 2020 ® User, Installation & Servicing Manual Issue 1.0 Dec 2020 ErP COMPLIANT J A N U A R Y 2 0 2 1 w w w . p o w r m a t i c . c o . u k...
  • Page 2 1. The appliance type and serial number. 2. The original commissioning documentation. As much detail as possible on the fault. 3. Your supplier, or installer, will then contact Powrmatic to make a guarantee claim on your behalf. Conditions of Guarantee 1.

  • Page 3: Table Of Contents

    Contents Users, Installation and Servicing Instructions CONTENTS Title Section Contents Page User Instructions Pre Installation Introduction Duties Dimensions Flue Options Heater Options & Accessories Technical data General Requirements Assembly Installation Fitting the unit Fitting the Flue/Combustion Air General Identification of Electrical Items Electrical Cable Installation Wiring Diagrams Commissioning and Testing...
  • Page 4 User Instructions D) Description of Operation If the heater has not been left operational proceed as follows. Important: The heater must NOT be controlled by switching ON and OFF the A) Checks before operating the Air main electrical supply to it. Heater 1) Standard Units The burner start up sequence will commence when the...

  • Page 5: Introduction

    IMPORTANT and draw in air for combustion. The air heater must be connected to a flue system that is approved by Powrmatic Service and Maintenance Engineers shall Ltd. ensure that replacement items are fitted,...
  • Page 6 Technical Specification Model High Fire (max) 15.0 20.5 25.3 30.1 34.9 39.9 49.1 59.1 69.8 88.4 119.2 138.3 Output (nominal) Low Fire (min) 10.5 11.7 16.1 16.1 19.8 23.8 29.9 34.0 41.2 67.7 72.7 High Fire (max) 16.2 22.2 27.4 32.1 35.8 43.1...
  • Page 7 SALVAGNINI: DRAWING NUMBER: TA19 9PS. LX F - Freeblowing Units Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC UNSPEC. TOLS. DESCRIPTION: chrisbromfield 06/01/2021 NEW DRAWING Hole centers ±0.1mm...
  • Page 8 DRAWING NUMBER: TA19 9PS. LX Duo - Axial Fan Bi-Directional Units Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC UNSPEC. TOLS. DESCRIPTION: 07/01/2021 NEW DRAWING Hole centers ±0.1mm...
  • Page 9 250.5 250.5 250.5 250.5 250.5 250.5 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC DESCRIPTION: UNSPEC. TOLS. 06/01/2021 NEW DRAWING Hole centers ±0.1mm LIMITED. It must not be used without their knowledge, nor...
  • Page 10 DRAWING NUMBER: DØ TA19 9PS. LX CCF - Centrifugal Close Coupled Fan Units Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC UNSPEC. TOLS. 337.5 DESCRIPTION: 337.5 337.5 06/01/2021...
  • Page 11 DRAWING NUMBER: TA19 9PS. LX D - Ducted Heat Module Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC DESCRIPTION: UNSPEC. TOLS. 06/01/2021 NEW DRAWING Hole centers ±0.1mm LIMITED.
  • Page 12 Dimensions Flue and Flue Components Concentric Horizontal Terminal Size A mm B mm C mm D mm E mm 130mm 80-100mm 80-100mm 130mm Concentric Vertical Terminal Size A mm B mm B1mm C mm D mm E mm E1 mm 1395 1515 1850...
  • Page 13 Dimensions Flue and Flue Components 90° Elbow 45° Elbow Size A mm B mm Size A mm B mm Flue Options Single Flue type B22 The flue system will take form of individual components. Type B22 installation - Exhaust Only system components A Vertical terminal or B Horizontal terminal C Adjustable flue lengths...
  • Page 14 Flue Options Balanced Flue type C12 or C32 Kits The flue kit will take form of the following components: Type C32 installation - Vertical Balanced Flue kit A Vertical terminal* B Single to twin adaptor (ski boot)* C Adjustable flue lengths x 2 D In-line condense drain E 250mm standard flue length F Terminal extension length*...

  • Page 15: Heater Options & Accessories

    SALVAGNINI: DRAWING NUMBER: TA19 9PS. LNVx - Mixing Box Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk This drawing is copyright and the property of POWRMATIC DESCRIPTION: UNSPEC. TOLS. 02/07/2018 NEW DRAWING Hole centers ±0.1mm LIMITED. It must not be used without their knowledge, nor...
  • Page 16 Tel: 01460 53535 Fax: 01460 52341 Web: www.powrmatic.co.uk E mail: r&d@powrmatic .co.uk POWRMATIC LTD MATERIAL GAUGE & SPEC: TITLE: DO NOT SCALE This drawing is copyright and the property of POWRMATIC UNSPEC. TOLS. DESCRIPTION: "Title Here" 16/07/2018 NEW DRAWING UNITS: "Material Gauge &...

  • Page 17: Technical Data

    1.2 Technical Data Injector Sizes & Burner Pressures - Natural Gas - Group H - G20 Net CV (Hi = 34.02MJ/m³) (All variants) High Fire Low Fire Burner Burner Injectors Gas Rate Gas Rate Pressure Pressure MODEL Size (mm) Marked mbar m³/h mbar...

  • Page 18: General Requirements

    Powrmatic heaters are designed to operate within an appertaining to the area in which the heater is located, ambient temperature range of -10 to 25°C.
  • Page 19 1.3 General Requirements 1.3.5 Flue System Only approved flue systems may be used with these units and must be installed to current standards and rules in force. Type C32/C62 Installation. The heater position must permit the provision of a satisfactory run of flue system and an adequate air supply.
  • Page 20 1.3 General Requirements 1.3.6. Related Documents gas undertaking or a local gas undertaking contractor. An existing meter should be checked, preferably by the gas All Gas Fired heaters comply with the following European undertaking, to ensure that the meter is adequate to deal Directives: with the total rate of gas supply required.
  • Page 21 1.3 General Requirements • Mechanical Ventilation: • Mechanical Ventilation: Must ensure that the space air change rate is at least The minimum flow rate of ventilation shall be 4.14m³/h 0.5/h, must be of the ‘input’ type and interlocked to per kilowatt of total rated heat input. ensure the heaters cannot work if the input system is not Type C flued installations.
  • Page 22 1.3 General Requirements Direct to outside air causing an electrical thermal trip condition. (e.g. by Low level (inlet) 5cm²/kw of total rated net heat input adjustment of duct outlet nozzles and balancing of the High level (outlet) 5cm²/kw of total rated net heat input. duct system).
  • Page 23 1.3 General Requirements Where the heater is installed in a plant room, the return and fumes, and where there is any possibility of pollution air intake(s) and the warm air outlet(s) from the heater(s) of the air by dust, shavings etc., precautions must be must be fully ducted, into and out of the plant room to taken to prevent contamination.
  • Page 24 1.4 Assembly 1.4.1.2. Downturn Heads 1.4.2. LX 'DUO' (Bi-Directional) These are supplied as an option and are fitted in place of The heater is suppled with two loose air deflector baffles the horizontal louvre utilising the original fixings. to be assembled on-site. One to be fixed to the front of the heater and one to be fixed to the rear.
  • Page 25 1.4 Assembly On larger Centrifugal units, the blower assembly is supplied loose for transportation purposes and will have to be assembled in-situ. The assembly is carefully offered to the rear of the heater and fixed utilising the panel screws suppled. Any loose electrical wiring is completed as per section 2.5 1.4.5.

  • Page 26: Fitting The Unit

    2.1 Fitting the Unit 2.1.1 Fitting space requirement LX F & C Front View LX Duo Front View R/H Side Views LX F LX C R/H Side Views LX V LX DUO page no. 26 of 68 X Range Users, Installation & Servicing Instructions Doc Ref M110 issue 1.0 Dec 2020.
  • Page 27 Note: Unpack and check the contents are undamaged and conform to the packing list. All Powrmatic heaters have been fired, preset and fully tested to stringent approved test procedures prior to Please inspect packages before signing as a claim will dispatch.
  • Page 28 2.1 Fitting the Unit appertaining to the area in which the heater is located, b) on specifically designed cantilever brackets from a non particularly where special risks are involved such as combustible wall. areas where petrol vehicles are housed, where cellulose c) on a level noncombustible surface.
  • Page 29 2.1 Fitting the Unit 2.1.4. Air Distribution System Recommended maximum drop rod length is 1.8m. 2.1.4.1. General LX F Permanent LX F/Duo discharges air in two directions, significantly suspension enhancing the effective coverage of the heater and supports leading to a more even warmth distribution especially within modern well insulated buildings.
  • Page 30 2.1 Fitting the Unit 2.1.5. Gas Connection conductors become taut before the earth conductor if the cable or cord slips out of the cord anchorage. All external Gas Safety (Installation & Use) (Amendment) controls must be of an approved type. Regulations It is law that the final connection to all gas 2.1.7.
  • Page 31 2.2.1 General brackets, or equivalent, must be used to provide lateral stability and should be used at centres not exceeding 2.5 Only flue systems supplied through Powrmatic Ltd may metres. be used with this appliance. Twin Wall Flue can also be used.
  • Page 32 Male end during installation If shorter lengths of flue are required then Powrmatic Female end supply an adjustable length which provides adjustment between 75-230mm. In extreme circumstances, and where an adjustable...
  • Page 33 2.2 Installation of Flue System/Combustion Air 2.2.4.1 Vertical Balanced Flue Cross sectional area detailing sealing arrangement. Locking Assembly type C32 Adjustable Band Locking Seal IMPORTANT: The maximum length for a Band is 6 metres. balanced flue system The maximum length of flue is subsequently Slip Section Inner Tube shortened if bends are added to the planned...
  • Page 34 2.2 Installation of Flue System/Combustion Air Typical Vertical Balanced Flue Slide a condense length fully into the exhaust air spigot and 250mm standard length fully into the combustion air type C32 - exploded view spigot of the heater (a smear of paraffin will ease fitting). Place an adjustable length locking band onto each end of the condense and 250mm standard length ensuring the rubber gasket is the correct way round (see section...
  • Page 35 2.2 Installation of Flue System/Combustion Air 2.2.4.2 Horizontal Balanced Flue Check that the spigots on the heater contain their seals. Assembly type C12 Slide a 250mm length fully into the exhaust air spigot and another into the combustion air spigot of the heater (a IMPORTANT: The maximum length for a smear of paraffin will help ease fitting).
  • Page 36 2.2 Installation of Flue System/Combustion Air 2.2.4.3 Vertical Single Flue Assembly Place a vertical terminal into the open end and clamp into place using a locking band. (This locking band may be very type B22 tight!, see section 2.2.3.1 for correct installation). IMPORTANT: The maximum length for a Check that the exhaust air spigot on the heater contains a...
  • Page 37 2.2 Installation of Flue System/Combustion Air Typical Vertical Balanced Flue 2.2.4.4 Horizontal Single Flue type B22 - exploded view Assembly type B22 IMPORTANT: The maximum length for a is 12 metres. balanced flue system The maximum length of flue is subsequently Vertical Roof Terminal shortened if bends are added to the planned flue run.
  • Page 38 (i.e. sewer carries both rainwater & foul water). Alternatively, the condensate We recommend installing a Powrmatic inline condense can be discharged into a purpose made soakaway. A flue drain when flued vertically, due to the lower flue gas...

  • Page 39: General Identification Of Electrical Items

    2.3 General Identification of Electrical Items EXHAUST FAN LOW FIRE GAS VALVE PRESSURE SWITCH HIGH FIRE PRESSURE SWITCH RECTIFICATION SENSOR IN-SHOT BURNER SPARK PROBE LIMIT STAT FUSE FAULT INDICATION HIGH LIMIT RESET MAINS SECOND HIGH LIMIT RESET. INPUT (Opposite Side 90-140 only) CONTRACTORS TERMINALS PACTROL...

  • Page 40: Electrical Cable Installation

    Note: To achieve maximum system efficiency flexible conduit. it is recommended that units are controlled by a Powrmatic MC200 or MC300 unit. Simple room thermostat and thermostat/time clock The local electrical supply conditions must be compatible control systems will not provide optimum system with the electrical data given on the appliance data plate.
  • Page 41 New Drawing instructions supplied with controller for wiring sizing, 25.11.20 Max. 100m) This drawing is copyright and the property of POWRMATIC LIMITED. It must not be used without DATE MODIFICATION their knowledge, nor communicated to any other person or company.
  • Page 42 2.4 Electrical Cable Installation 2.4.4. Control Wiring * when used Warning: External controls MUST be powered via heater terminal 10, 11 and Earth 2.4.5. External Fuses 3 phase options shown in italics F - Free Blowing Unit C - Centrifugal Unit Running Running Fuse/MCB Rating (A)
  • Page 43 2.4 Electrical Cable Installation 2.4.6. Interconnecting Wiring: 2.4.6.1. LX Modulation to Remote MC200 Warning: External controls MUST be powered via heater terminal 10, 11 and Earth *2.4.6.2. LX High/Low to Remote Control *2.4.6.3. LX On/Off to Remote Control Key: Lockout Reset Key: Lockout Indication Lockout Reset...
  • Page 44 2.4 Electrical Cable Installation 2.4.6.4 LX Modulation Interconnections to Optional Master and Slave MC300 2.4.6.5 LX Modulation BMS Interface Interconnections (Option 1) Option 1 - no heat enable required, heater fires when modulation voltage is applied (0V OFF, 10V HIGH FIRE). Inputs from BMS page no.

  • Page 45: Wiring Diagrams

    2.5 Wiring Diagrams 2.4.6.6 LX Modulation BMS Interface Interconnections (Option 2) *Option 2 requires a HEAT ENABLE signal from the BMS Input from BMS Inputs from BMS * BMS Interface Boards will be factory fitted and attached to the outside of the heater.
  • Page 46 2.5 Wiring Diagrams LX F15-140 & LX C15-30 1 Pha Internal Wiring Dwg. H01GBE0355 page no. 46 of 68 X Range Users, Installation & Servicing Instructions Doc Ref M110 issue 1.0 Dec 2020.
  • Page 47 2.5 Wiring Diagrams LX C35-140 1 Pha Internal Wiring Dwg. H01GBE0386 page no. 47 of 68 LX Range Users, Installation & Servicing Instructions Doc Ref M110 issue 1.0 Dec 2020.
  • Page 48 2.5 Wiring Diagrams LX Downflow supplementary wiring Dwg. H01GBE0255 Heater Terminals Fan Demand Terminal Grn/Ylw Earth Stud Cewal Thermostat p/n 143000534 3 core cable 0.75mm LX F 15, 20, 25, 30, 40 & 45 Axial Fan supplementary wiring Wh/Blu Brown Grn/Y Wh/Bro Blue...
  • Page 49 2.5 Wiring Diagrams LX F 50, 60, & 70 Axial Fan supplementary wiring Brown Blue Grn/Y Blue Grn/Yel Heater wiring Grey Brown Grey Main Fan LX F 90, 120 & 140 Axial Fan supplementary wiring Brown Blue Blue Grn/Y Grn/Yel Grn/Yel Grey Heater wiring...
  • Page 50 2.5 Wiring Diagrams LX35 C to 140 C Single Phase Fuse Schedule Refer to Dwg M01GBE0387 Fuse Schedule Model Fuse 1 Part No. Fuse 2 Part No. LX C35 & 40 T10A 140700040 LX C50, 60 & 70 T12A 140700042 LX C90 T10A 140700040...

  • Page 51: Commissioning And Testing

    * Gas Safe Registered Engineer Particular attention should be given to the correct All Powrmatic heaters have been fired, preset and fully tested to stringent approved test procedures prior to arrangement of delivery ducts and registers, return air dispatch.
  • Page 52 2.6 Commissioning and Testing 2.6.5. Operating the Air Heater NOTE: A short press of the ENGINEER TEST button will switch between high and low fire. NOTE: On initial lighting of the heater(s), it may Press and holding the ENGINEER TEST button take some time to purge the internal gas pipe for 2 seconds will shut the heater down.
  • Page 53 2.6 Commissioning and Testing 2. Minimum current reading is 0.5µA and normal value Shaft Adjustment nut (7mm) should be 1.5µA or higher. for maximum pressure setting Adjustment nut (9mm) for minimum pressure setting ‘O’ ring 6.3mm AMP terminals Flame Current Measurement 2.6.9.
  • Page 54 2.6 Commissioning and Testing 2.6.10. Limit Thermostat 2. Check that the room thermostat and all automatic controls are operating satisfactorily. Limit Thermostat settings:- 2.6.12. Handing over the Air Heater LX15-30 = 90°C LX35 = 110-120°C Hand these instructions to the user or purchaser for LX40-140 = 90°C retention and instruct in the efficient and safe operation...
  • Page 55 2.7 Servicing 2.7.2. Main Burner Assembly Removal 2.7.4. Exhaust Fan 1. Ensure that the gas service valve is turned OFF 1. Remove the four screws securing the flue outlet socket. and then unscrew the union nut situated immediately downstream of it. 2.
  • Page 56 10 - 12mm forward of the Components burner. Only parts supplied via or authorised by Powrmatic 2.7.7.4. Limit Thermostat should be used. A short list of parts and part numbers are detailed in section 3.2 of this manual. If in doubt, please contact Powrmatic.
  • Page 57 2.7 Servicing 3. Remove the securing nut and remove thermostat from Settings (Pa) the front panel. Model Low Fire High Fire 4. Fit replacement thermostat in reverse order. LX15 Note*: LX35 & 90 - 140 units have a second limit stat at the opposing end of the heater to LX20 the burner/controls.
  • Page 58 2.7 Servicing 2.7.7.10. Run/Fault Indicator Lamp 3. Fit replacement in reverse order. Situated at the bottom of the front panel. 2.7.7.8. R2R Main Control Board 1. Disconnect the electrical plug from the R2R board 1. Unplug all the electrical connections by squeezing each side to release.

  • Page 59: Fault Finding & Status Indication

    3.1 Fault Finding and Status Indication 3.1.1. Heater LED Indication Located on the front of the heater at the bottom right hand corner. Colour / State Fault indication Possible cause of fault On Steady Standby Faulty pressure switch, incorrectly set, 1 Pulse APS1 FAULT incorrectly wired, pick up tube fault.
  • Page 60 3.1 Fault Finding and Status Indication 3.1.2. R2R Main Board Indication Located at the bottom left hand corner of the R2R Main Board. Colour State Indication No lockout On steady LOCKOUT Combustion fan OFF Combustion fan Running at speed Slow Flashing FAN FAULT 3.1.3.
  • Page 61 3.1 Fault Finding and Status Indication Is there Is the Is there 230V between No call for heat! AMBER LED on the <2Vdc between Pactrol controller terminals front of the heater terminals t8 & Check controller! CON5 - pin 3 and pulsing.
  • Page 62 3.1 Fault Finding and Status Indication Continued from previous page there NOW a Replace spark present Pactrol! at the ignition Electrode? • Ensure spark gap is 2.5mm Is a there • Ensure there are no cracks on spark present and NOW a the ceramic Replace...

  • Page 63: List Of Parts

    3.2 List of Parts Item Description Usage Part No. Gas Valve SIGMA 845 15-50 145035208M-SIT Gas Valve VR4605PB 70-90 145035204M Gas Valve VR425PB 120/140 141378715M 15-70 142423010 Ignition Electrode 90-140 142423004 Rectification (Flame Sensor) Probe 142423003 15-70 142400240 Burner 90-140 142400241 142403609 Limit Stats...
  • Page 64 3.2 List of Parts 15-30 & 40 NV2XSTD01201 NOx Insert Assembly 35 & 50-70 NV2XSTD01203 90-140 NV2XSTD01202 Swirler (turbulator) 15-70 NVXSTD00502 Tri Coloured Indicator 147600155 NTC 100k Thermistor 143000860 Temp Range -20 - 210C 146522176 Low Fire Pressure Switch High Fire Pressure switch 146522177 15-50 140210496M...
  • Page 65 3.2 List of Parts LX C 120-140 3Ph 143000800B Overload LX C 120-140 3Ph 143000800 15/25 1 x 150000025 1 x 150000035 2 x 150000045 2 x 150000055 EU1 Filter (When uses with filter box) 2 x 150000065 3 x 150000075 3 x 150000085 3 x 150000075 page no.
  • Page 66 Appendices Information required for ecodesign (ErP) Directive 2009/125 Model Rated Heat Capacity 15.0 20.5 25.3 30.1 Minimum Heat Capacity 10.5 11.7 16.1 High Heat Input 16.2 22.2 27.4 32.1 Low Heat Input Nett CV 11.0 12.2 16.5 High Fire Useful Energy Low Fire High Fire Low Fire...
  • Page 67 Notes: page no. 67 of 68 LX Range Users, Installation & Servicing Instructions Doc Ref M110 issue 1.0 Dec 2020.
  • Page 68 Energy Association Powrmatic pursues a policy of continues improvement in both design and performance of its products and therefore reserves the right to change, amend or Powrmatic pursues a policy of continues improvement in both design and performance of its products and therefore reserves the right to change, amend or vary specifications without notice.

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