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Powrmatic PTUL 25 Installation And Operation Instructions Manual

Powrmatic overhead radiant tube heaters
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INSTALLATION AND OPERATION INSTRUCTIONS

OVERHEAD RADIANT TUBE HEATERS
Models: PTUL 25, PTUL 30, PTUL 35, PTUL 40, PTUL 45,
Single Stage Pull Through System (Negative Pressure)
OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and understood before
installing, operating or servicing this heater. This heater is intended for use with either Natural Gas or Propane
Gas. It must be installed by a qualified service person or a licensed contractor in accordance with state and local
codes.
▲WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property damage,
injury or death. Read the installation, operation and maintenance instructions thoroughly before installing or
servicing this equipment. For assistance or additional information, consult a qualified installer, service agency or
the gas supplier.
INSPECT all combustion air openings into the building and, if necessary, clear if they become blocked by dust.
FOR YOUR SAFETY: If the heater is installed without a flue, exhaust fans MUST be operating on an appropriate
cycle when heaters are operating to avoid a high concentration of carbon monoxide. When used without fresh
air, this heater may give off carbon monoxide, an odorless and poisonous gas. CARBON MONOXIDE POISONING
MAY LEAD TO DEATH. Early signs of carbon monoxide poisoning resemble the flue with headaches, dizziness and
nausea. If you experience these signs, GET FRESH AIR IMMEDIATELY! Have the heaters serviced as soon as
possible and check the ventilation in the house.
These heaters are designed for agricultural applications and may operate with the use of either Natural Gas or
Liquid Propane (LP) Gas. Check the heater's nameplate to determine the correct gas type before proceeding
with installation.
!INSTALLER: This manual is the property of the owner. Please present this manual to the owner when you leave
the job site.
IF YOU SMELL GAS:
! DO NOT try to light any appliance.
! DO NOT touch any electrical switch; DO NOT use any
telephone in your building.
! IMMEDIATELY call your gas supplier from a neighbor's
telephone. Follow the gas supplier's instructions. If you
cannot reach your gas supplier, call the fire department.
!IMPORTANT: SAVE THIS MANUAL FOR FUTURE REFERENCE.
Tel: +44 (0) 1460 53535, Fax: +44 (0) 1460 52341 www.powrmatic.co.uk
PTSL 25, PTSL 30, PTSL 35, PTSL 40, PTS L45
FOR YOUR SAFETY
Powrmatic Ltd
Hort Bridge, Ilminster, TA19 9PS
DO NOT store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
Form #44201150
Sept 2010

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Summary of Contents for Powrmatic PTUL 25

  • Page 1: Installation And Operation Instructions

    INSTALLATION AND OPERATION INSTRUCTIONS OVERHEAD RADIANT TUBE HEATERS Models: PTUL 25, PTUL 30, PTUL 35, PTUL 40, PTUL 45, PTSL 25, PTSL 30, PTSL 35, PTSL 40, PTS L45 Single Stage Pull Through System (Negative Pressure) OWNER / INSTALLER: For your safety this manual must be carefully and thoroughly read and understood before installing, operating or servicing this heater.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE 1.0) Safety ..............................2 2.0) Installer Responsibility ........................2 3.0) General Information .......................... 2 4.0) Minimum Clearances to Combustibles................... 4 5.0) Specifications ............................. 5 6.0) Packing List............................7 7.0) Dimensions – U Tube Configurations....................11 7.1) Heater assembly overview –...

  • Page 3: Safety

    Ventilation requirements are addressed further in these instructions. Although these heaters may be used in many applications other than space heating (e.g., process heating), Powrmatic will not recognize the warranty for any use other than space heating. Form #44201150...
  • Page 4 This heater is not an explosion proof heater. Where the possibility of exposure to volatile and low flash point materials exists, it could result in property damage or death. This heater must not be installed in a spray booth where the heater can operate during the spraying process. Consult your local fire marshal or insurance company. Linear Configuration Series Only: Since linear configuration tube heaters are always hotter at the control end than at the flue terminal end, always observe the minimum recommended mounting heights.

  • Page 5: Minimum Clearances To Combustibles

    NFPA54 requires that the installer must post signs that will “specify the maximum permissible stacking height to maintain the required clearances from the heater to combustibles.” Powrmatic recommends posting these signs adjacent to the heater thermostat or other suitable location that will provide enhanced visibility.

  • Page 6: Specifications

    PN 4260360C Fan Air Restrictor Plate None None Electrical Supply 230V~50Hz 125W Fuse Externally Dimensions PTUL 25: 5.385m x 0.465m PTSL 25: 10.065m x 0.34m Weight PTUL 25: 47kg PTSL 25: 46kg Gas Connection R - ½ Flue Size Ø100mm...
  • Page 7 Table 5 MODEL PTUL 40/PTSL 40-N PTUL 40/PTSL 40-L Heat Input 42.2kW Hs 38.0kW Hi Appliance Type (II A2, B 2H3P Appliance Category 2H3P Adjusted for 2H G20 20mbar 3P G31 37mbar Setting Pressure 12.5mbar 25mbar Injector Ø 5.0mm Ø 3.3mm Burner Baffle Plate PN 4260360S PN 4260360S...

  • Page 8: Packing List

    6.0) PACKING LIST PTUL 25 The appliances are supplied as follows:- Table 7 PART NO. MODEL PTUL 25 Carton (containing the following) Fastenings Pack Burner Box Assembly 44438010 Fan Assembly – 3” (less air plate) 4260021 U-Bend 4260372 Hanger Bracket...
  • Page 9 PTUL 30/35 PTUL 40/45 The appliances are supplied as follows:- Table 8 PART NO. MODEL PTUL 30 PTUL 35 PTUL 40 PTUL 45 Carton (containing the following) Fastenings Pack Burner Box Assembly 44438020 Fan Assembly – 4” (with air plate) 44438030 Fan Assembly –...

  • Page 10: 44438010 Fan Assembly - 3" (Less Air Plate)

    PTSL 25 The appliances are supplied as follows:- Table 9 PART NO. MODEL PTSL 25 Carton (containing the following) Fastenings Pack Burner Box Assembly 44438010 Fan Assembly – 3” (less air plate) 4260245 Hanger Brackets 4267923 Torctite Coupling 4260020 Radiant Tube (Ø 76.2 x 4572) 4260176 Reflector Panel (3035 long) 4260244...
  • Page 11 PTSL 30/35 PTSL 40/45 The appliances are supplied as follows:- Table 10 PART NO. MODEL PTSL 30 PTSL 35 PTSL 40 PTSL 45 Carton (containing the following) Fastenings Pack Burner Box Assembly 44438020 Fan Assembly – 4” (with air plate) 44438030 Fan Assembly –...

  • Page 12: Dimensions - U Tube Configurations

    7.0) DIMENSIONS – U TUBE CONFIGURATIONS Fig. 9 Fig. 10 Form #44201150 Sept 2010 -11-...
  • Page 13 Fig. 11 Form #44201150 -12- Sept 2010...

  • Page 14: Heater Assembly Overview - U Tube Configurations

    7.1 HEATER ASSEMBLY OVERVIEW – U TUBE CONFIGURATIONS Fig. 12 Form #44201150 Sept 2010 -13-...
  • Page 15 Fig. 13 Form #44201150 -14- Sept 2010...
  • Page 16 Fig. 14 Form #44201150 Sept 2010 -15-...

  • Page 17: Dimensions - Linear Tube Configurations

    8.0) DIMENSIONS – LINEAR TUBE CONFIGURATIONS Fig. 15 Form #44201150 -16- Sept 2010...

  • Page 18: Heater Assembly Overview - Linear Tube Configurations

    8.1) HEATER ASSEMBLY OVERVIEW - LINEAR TUBE CONFIGURATIONS Fig. 16 Form #44201150 Sept 2010 -17-...
  • Page 19 Fig. 17 Form #44201150 -18- Sept 2010...
  • Page 20 Fig. 17a Form #44201150 Sept 2010 -19-...

  • Page 21: Typical Suspension Methods

    The appliance should be located with respect to building construction and other equipment to permit access to the appliance for servicing etc. Powrmatic recommends that the body sections be suspended using chains with turnbuckles. This will allow slight adjustments after assembly and heater expansion/ contraction during operation.

  • Page 22: Burner Box Support Details

    Fig. 18 9.1) BURNER BOX SUPPORT DETAILS The burner box must be supported with a welded chain after overall heater suspension is complete. This is to prevent burner from sagging which may cause the tube to burn tube out prematurely. Assemble bracket and turnbuckle to inlet end of burner as shown.

  • Page 23: User Instruction Label

    9.2) USER INSTRUCTION LABEL The User Instruction label shown below is supplied with each heater. Affix this label adjacent to low level user controls, such as thermostats, time clocks or control panels. OVERHEAD RADIANT HEATER OPERATING INSTRUCTIONS Fig. 20 10.0) TYPICAL HEATER ASSEMBLY See heater dimensions and assembly overview (Sections 7.0 through 8.1) for each U-model and Linear model configurations.

  • Page 24: Tube Coupling Details

    11. Slide reflector panels and space between burner box and U-bend (U-model heaters only) as indicated on heater dimension drawings. Reflectors must overlap approximately as shown on the dimension drawings. 12. Secure reflectors to tube support/hanger brackets using the screws and clamps (supplied in fastening kits). Note: Refer to details A or B of each assembly overview drawing for the required open or closed positions of the clamps.

  • Page 25: Inserting Turbulators

    Once all the heater body sections are attached, make sure that the heater system is level. If it is not, slight adjustments can be made using the turnbuckles. (See Section 7.0) Fig. 23 Important: NEVER reuse a coupling. Always install a new coupling only and torque as per instructions above and the diagrams above.

  • Page 26: Attaching U-Bend

    Heaters Heaters MODEL Turbulator Sections Burner Leg Fan Leg Fan End PTSL 25 65mm x 572mm PTUL 25 65mm x 572mm PTSL 30 90mm x 610mm 90mm x 610mm PTUL 30 90mm x 610mm PTSL 35 90mm x 610mm PTUL 35...

  • Page 27: Attaching Burner Box Assembly

    10.4) ATTACHING BURNER BOX ASSEMBLY Warning: LIGHTS MUST FACE DOWN. Failure to do so will result in overheating the ignition module and will invalidate the warranty. Fig. 26 Place a Torctite Coupling over the end of the Radiant Tube (refer to Section 10.1 “Tube Coupling Details”). Assemble the Burner Box to the Radiant Tube ensuring that it engages fully into the Torctite Coupling and is positioned vertically.

  • Page 28: Attaching Fan Assembly

    10.5) ATTACHING FAN ASSEMBLY Fig. 27 Place a Torctite Coupling over the end of the Radiant Tube (refer to Section 10.1 “Tube Coupling Details”). Assemble the Fan Assembly to the Radiant Tube and position the fan outlet pointing upwards for flueless applications.
  • Page 29 This appliance is equipped with a step-opening, combination gas valve. The maximum supply pressure to the appliance is 60 mbar. If the line pressure is more than the maximum supply pressure, then a second stage regulator which corresponds to the supply pressure must be used. After all gas connections have been made, make sure the heater and all gas outlets are turned off before the main gas supply is turned on slowly.

  • Page 30: Instructions For Pressure Test Gauge Connection

    12.0) INSTRUCTIONS FOR PRESSURE TEST GAUGE CONNECTION CHECKING GAS PRESSURES Switch off the electricity supply to the appliance. b. Connect a manometer to the test nipple protruding from the rear panel of the Control Box (adjacent to the Air Inlet Adaptor). See Fig. 31. Open the Control Box door after releasing the two toggle latches. Fig.
  • Page 31 25 mbar Fig. 32 d. Upon obtaining the correct burner setting pressure switch off the electricity supply to the appliance, remove the screwdriver, replace the plug into the upper surface of the control box door and open the door. Remove the manometer tube from the RIGHT (Gas OUT) Control Valve test nipple and screw in the test nipple sealing screw.

  • Page 32: Electrical Connections

    13.0) ELECTRICAL CONNECTIONS ELECTRIC SHOCK HAZARD The electrical wiring to this heater must be installed in accordance with the latest or current National Regulations and any Local Regulations, which apply. Electrical supply 230V~50Hz 125W Current rating 0.55 Fuse externally b. Twin core and earth PVC covered flexible supply cable (0.5mm2-to National or Local standard specification) must be used, with connection made as follows: Single Heaters per Thermostat connection diagram Fig.
  • Page 33 Internal Wiring Diagram Fig. 35 Form #44201150 -32- Sept 2010...

  • Page 34: Venting And Fresh Air For Combustion

    14.0) VENTING AND FRESH AIR FOR COMBUSTION POISONOUS GAS AND SOOT HAZARD These appliances may be installed with an exhaust flue fitted or without an exhaust flue fitted. A. FLUELESS (UNFLUED) The installation room should have a volume of at least 10m³/kw of installed nominal heat input of the radiant heater.
  • Page 35 VENTILATION BY NATURAL AIR CHANGE Gas-fired radiant heaters may be operated without any special exhaust system if the exhaust gases are discharged to the outside atmosphere by a sufficient natural air change in the installation room. Furthermore, no provision for thermal or mechanical ventilation is required in the following particular cases: Buildings with natural air change greater than 1.5 volumes per hour Buildings with a density of operating heat input not greater than 5W/m³...
  • Page 36 Note : first length is parallel section second length is concentric section. Fig. 36 16.1 Type A Outside (ducted) combustion air supply. When installed in a dusty or polluted atmosphere, the heater should be fitted with a ducted supply of clean fresh air. A length of 100mm flexible ducting should be installed between the Control Box Air Inlet and any rigid ducting and be secured to the Air Inlet with hose clips.
  • Page 37 Components Supplier Description Fig. 37 Form #44201150 -36- Sept 2010...
  • Page 38 16.4 TypeC The following figure shows the typical arrangements for concentric vertical flues, see table 12 for 90° bend equivalent lengths. The bends shown in the illustrations connecting the combustion air intake to the concentric ducts is calculated into the overall length. For example a system with one additional 150/100mm Ø...

  • Page 39: Lighting And Shutdown Instructions

    Type C fresh air connector 16.6 The connectors for the Type C fresh air are supplied as an accessory. The installation steps for the Type C connector are shown in figure 38a below. Fig. 38a 15.0) LIGHTING AND SHUTDOWN INSTRUCTIONS Ensure that the Control Box lid is closed and secured with the two toggle latches.

  • Page 40: Commissioning

    k. To shut down the appliance for longer periods of time, switch of the electricity supply to the appliance and turn off the gas supply at the gas isolation valve. NOTE: The lighting and shutdown instructions are also shown on a permanent label attached adjacent to the controls for the heater (see section 9.2).
  • Page 41 On completion of a service/fault finding task which has required the breaking and remaking of electrical corrections, the following checks, using a multi-meter must be made. 1. Earth continuity check 2. Polarity check 3. Resistance to earth check The contractor shall check the following during periodic maintenance. •...

  • Page 42: Troubleshooting Guide

    17.0) TROUBLESHOOTING GUIDE Form #44201150 Sept 2010 -41-...
  • Page 43 Form #44201150 -42- Sept 2010...

  • Page 44: Replacing Parts

    REPLACING PARTS ELECTRIC SHOCK & EXPLOSION HAZARD Only use genuine Powrmatic replacement parts. Parts are available from the factory for replacement by a licensed person. Refer to the Replacement Parts Guide in Section 21.0) for all replacement parts. IMPORTANT: Disconnect gas and electricity supplies to the appliance before carrying out any repair work. This work can be carried out at high level using a purposes designed access tower, but it is preferable that this work should be carried out at ground level.

  • Page 45: Removing Main Burner

    18.2) REMOVING MAIN BURNER Fig. 41 1. Open the control box door; unscrew the two M4 x 25 setscrews from the Burner Bracket and remove the Burner Clamp. 2. Unscrew the Burner from the Injector Fitting 3. Lift the burner out of the Control Box. 4.

  • Page 46: Removing Ignition Control

    18.4) REMOVING IGNITION CONTROL Fig. 43 1. Disconnect the 12 way Molex electrical connector and the grey HT ignition spark/flame sensor lead from the Ignition Control. 2. Unscrew the M3 screw securing the Ignition Control to the Control Valve. 3. Slide out the Ignition Control. 18.5) REMOVING AIR SWITCH Fig.

  • Page 47: Removing Gas Valve And Manifold Assembly

    18.6) REMOVING GAS VALVE AND MANIFOLD ASSEMBLY Fig. 45 1. After opening the control box door, disconnect the 12 way Molex electrical connector. 2. Disconnect the grey HT ignition spark/flame sensor lead from the ignition module. 3. Unscrew the two M4x25 setscrews from the burner bracket and remove the burner clamp. 4.

  • Page 48: Removing Air Inlet Plate

    18.8) REMOVING AIR INLET PLATE Fig. 47 1. After opening the control box door, disconnect tubing from both brass pressure test fittings. 2. Remove brass nut from pressure test fitting. 3. Disassemble components from the control box. 18.9) REMOVING THE FAN Fig.

  • Page 49: Conversion Instructions

    19.0) CONVERSION INSTRUCTIONS CONVERSION FROM CAT. 2H (Natural Gas) TO CAT. 3P (LPG) Remove the Injector from the Injector Fitting (see Section 18.3) and replace it with the alternative Injector supplied with conversion kit. Check that the size reference marked on the Injector agrees with that listed in the Specifications table (Section 5.0) for the appliance model in question.

  • Page 50: Replacement Parts Guide

    21.0) REPLACEMENT PARTS GUIDE The following is a list of replacement parts which may be required during the life of the appliance. CONTROL COMPONENTS Description Item No. Part No. Qty. 02330010 Vinyl Cap 02331010 Plug, Liquid Tight Hole 4262151 Inlet – Male Pin #PX0575 4262153 Outlet –...
  • Page 51 Label Neon 4262035 Label, Fan/Power Supply 4260420 Label, Warning - GB/IE 43344130GB Label, Clearances to Combustibles 42848180GB Label, Nameplate 4260440 Label, Operating Instructions - GB Label, Powrmatic Logo 44201150 Installation/Operation Manual Fan Assembly Description Item No. Part No. Qty. 4262256 Fan Unit –...
  • Page 52 Form #44201150 Sept 2010 -51-...

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