Transcript
The Package Heater Company
GAS FIRED UNIT HEATERS
MODELS· UH100 - UH140- UH180 - UH240- UH320
. INSTRUCTION MANUAL
Fort Road Littlehampton Sussex BN17 7EF
Tel: (0903) 725945
THE PACKAGE HEATER COMPANY
FORT ROAD
LlTTLEHAMPTON
SUSSEX BN17 7EF
Telephone: (0903) 725945
INSTALLATION, OPERATION, COMMISSIONING AND SERVICING INSTRUCTIONS
FOR PAK-A-WAY GAS FIRED UNIT HEATERS
Covers Models:
G.C. Numbers
UH100
42
675
22
UH140
42
675
23
UH180
42
675
24
UH240
42
675
25
UH320
42
675
26
THESE APPLIANCES HAVE BEEN APPROVED BY BRITISH GAS FOR USE ON NATURAL GAS
The Package Heater Company, whose policy is one of continuous development and improvement, reserve the right to alter any specification appearing in this manual without notification. IF IN ANY DOUBT ON THE INTERPRETATION OF ANY INSTRUCTIONS IN THIS MANUAL,
PLEASE CONTACT THE PAK-A-WAY SALES OFFICE, ADDRESS AND TELEPHONE NUMBER AS ABOVE.
CONTENTS
INDEX
lA lB lC
DESCRIPTION
PAGE NUMBERS
1Y lZ
Introduction ..................................................................................... 3
General requirements ......................................................................... 3
Heater unpacking .............................................................................. 4
Warranty......................................................................................... 4
Heater positioning ............................................................................. 5
Installation clearances ........................................................................ 6
Heater mounting ............................................................................... 6
Warm air distribution/circulation .......................................................... 6
Air supply ......................................................................................,,6
Flue installation ................................................................................ 8
Electrical supply ...............................................................................,9
Control panel (wiring box) ................................................................. 10
Time switch ................................................................................... 10
Room thermostat ............................................................................ 10
Room thermostat siting ............ .'....................................................... 11
Fan control switch ........., ................................................................. 11
Limit control switch ......................................................................... 11
Summer/Winter switch .....................................................................11
Flue venter .....................................................................................11
Venter wiring ..................................................................................13
Gas supply.....................................................................................15
Operation on LPG ..........................................................................,,15
Fitting LPG burner conversion sets .................................................... ,,16
LPG gas pressure settings .................................................................. 17
SECTION TWO TECHNICAL DATA
2
2
2
2
2
2
2
2
2
Natural Gas pressure settings .............................................................18
Injector size chart ............................................................................18
Performance ................................................................................. " 19
Dimensions.................................................................................... 19
Weights........................................................................................ 19
Mounting heights ............................................................................20
Gas control valve data ..................................................................... 20
Pilot ............................................................................................. 21
Thermocouple................................................................................ 21
SECTION THREE COMMISSIONING
3A 3B 3C 3D 3E 3F 3G 3H 3K 3L 3M
Electrical installation (General) ........................................................... 22
Gas installation (General). ..............................................................." 22
General installation checks .............................................................." 22
Lighting and pilot commissioning ....................................................... 22
Main burner commissioning .............................................................. 23
Testing the air heater ...................................................................... 24
Air heater operation cycle ................................................................ ,24
Gas control valve - Warning ............................................................. ,24
Air distribution - Adjustment ............................................................. 25
User's instructions/Advice to user..................................................... ,25
Service and spares/ Advice to use"r ...... ............................................... 25
General lighting instructions .............................................................. 25
SECTION FOUR SERVICING
4A 4B 4C 4D 4E 4F
General .........................................................................................27
WARNING .................................................................................... 27
Service instructions ......................................................................... 27
Re-commissioning ...........................................................................29
Service report ................................................................................ 29
Burner removal (photograph) ............................................................ 29
SECTION FIVE FAULTS & REMEDIES
5A
(j)Pilot problems ..............................................................................30
(ii)Burner problems ..........................................................................30
(iii)Fan problems .............................................................................31
SECTION SIX SPARES LIST
6A 6B
Spares UH100-UHl40-UHl80 ............................................................32
Spares UH240-UH320 ......................................................................33
SECTION SEVEN WIRING DIAGRAMS
23301 EUH Air heater (internal) ......................................................................34
0998 EUH (24v) /0999 EUH (240v)
External controls (thermostats, timeswitches, Summer/Winter switches ............35/36
23302 EUH Flue venter. ........ .................".......................................................37
SECTION ONE INSTALLATION
10
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lJ lK lL 1M
IN lP lQ
lR 1S 1T lU lV lW 1X
3J
2
SECTION ONE INSTALLATION
1A INTRODUCTION PAK-A-WAY Model U. H. air heaters are compact natural draught gas fired automatic horizontal heaters, range rated with outputs between 29.3 kw (100,000 Btu/h) and 93.7 kW (320,000 Btu/h). Natural Gas units supplied unless otherwise specified. They are equipped with powerful axial fans fitted at rear of heater and are primarily intended for heating commercial or industrial premises. They can be suspended anywhere in the space to be heated from hangers provided on cabinet top, or can be mounted on non-combustible supports where they heat the flow of circulating air controlled in elevation by adjustable horizontal louvres. A socket for sheet metal flue systems i~ provided on top or can be site interchanged to give a rear flue outlet. Built in aluminised steel draught diverter is integrally mounted within the air heater. Each air heater must be connected to an individual open flue system. The enclosed controls and removable burner rack assembly are accessible through a removable side panel. Standard units are equipped with a low voltage control system and thermocouple actuated safety relay with manual reset button on the electro magnetic gas control valve. Cabinet is made of cold rolled, phosphate treated steel panels and corner sections. Finish stove enamel PAK-A-WAY blue. Heat exchanger fitted as standard is multiple all welded aluminised steel. These instructions are intended to provide a guide to the procedure for a systematic check up of the installation arrangements and of possible faults in the air heater arising during the handling and installation. It is recommended that this check up be carried out during and/ or at the completion of the installation and should not wait until the air heater is actually required, so that any work needing attention can be carried out in ample time. Whilst in most cases all will be found to be in order, this check up will save a great deal of time and expense in tracing any faults which may exist. When installing PAK-A-WAY gas fired Unit Heaters the following points require to be carefully considered. (a) Position of air heater for the distribution and general circulation of warmed air. (b) Air Heater mounting height level. If it is found that site circumstances require a higher mounting height than that recommended elsewhere in this manual, it may be possible to overcome the stratification/circulation problems which will generally occur with high level mounting by using a PAK-A-WAY'RECOUPAK' Energy saving fan system in conjunction with the heating installation. Contact the Package Heater Co. Ltd., Sales office for further information. (c) Ensure that the air heater position and mounting height allows for safe service and maintenance access and for adequate clearance for removal of the burner tray assembly and fan assembly if required. (d) Position of air heater for flue route. (e) Position of air heater for gas pipe route. (f) Position of electrical fused isolator, timeswitch, thermostat etc. in relation to area being heated and routing for wiring back to air heater.
ALL PAK-A-WAY GAS FIRED UNIT HEATERS MUST BE COMMISSIONED, TEST FIRED AND SERVICED BY A COMPETENT GAS ENGINEER.
1B GENERAL REQUIREMENTS SAFETY NOTE The installation of the air heater(s) must be in accordance with the relevant requirements of the GAS SAFETY REGULATIONS, BUILDING REGULATIONS and the I.E.E. REGULATIONS. It should be in accordance also with any relevant requirements of the LOCAL GAS REGION, LOCAL AUTHORITY and FIRE AUTHORITY and the relevant recommendations of the following documents:
3
BRITISH STANDARD CODES OF PRACTICE CP 331 Installation of Pipes and Meters for Town Gas, Part 3 Low pressure installation pipes;
CP 3 Ch. IV precautions a~ainst fire. Part 2 Shops and Departmental Stores; Part 3 Office Buildings
and the relevant standards of the following document:
'Standards of Installation for Gas Fired Industrial Warm Air Heaters' (published by the Industrial Warm Air Heater Manufacturers Association Limited). Where air heaters are used in installations where the total input is less than 60 kW then BS5864 Installation of gas-fired ducted-air heaters of rated input not exceeding 69 kW, and BS5440 Flues and air supply for gas appliances of rated input not exceeding 6OkW, Part 1 Flues, Part 2 Air supply must also be followed. The above related documents are, from time to time, revised and additional documents published. Whilst every effort is made to keep literature current, Package Heater Co. Ltd. cannot be responsible for this listing being correct or complete at the time of issue. Account must also be taken to ensure that installation is carried out in strict accordance with any insurance company's requirements appertaining to the area in which the air heater(s) is located. The air heater must not be installed in conditions for which it is not specifically designed, e.g. where the atmosphere is highly corrosive or salty and where high wind speeds may affect the burner operation. Suitable protection should be provided for the air heater(s) when they are located in such a position that external mechanical damage may be sustained due to such things as fork lift trucks or overhead cranes. 1C HEATER UNPACKING Whilst every care is taken to ensure that the air heater(s) is delivered in good condition, upon receipt an immediate inspection should be carried out to check for any damage which may have been incurred in transit. If any damage is found it should be reported to the Package Heater Co. Ltd . Sales Office within TWO working days of delivery and must be immediately confirmed in writing, otherwise claims will not be accepted. The heater(s) has been fired on Natural Gas and inspected at the factory immediately prior to being crated and packed and was in good condition at that time. The heater is supplied mounted upon a wooden pallet, with timber packing to protect the fan cage and is enclosed within a cardboard carton which is held with securing bands. To prevent scuffing of the paintwork on the base, do not remove air heater from pallet (to which it is secured by means of two metal clips and coachscrews) until heater is positioned if suspended from eyebolts, or immediately prior to positioning on a non combustible surface or metal cantilever brackets. To unpack the heater cut the securing bands, remove all staples holding carton to pallet and timber packing, lift carton upwards and clear to expose the timber corner packing, which can then be removed. Check that the air heater is correct as described on the delivery note and with the order requirements. The air heater can now be moved on the pallet to its installation location. To remove air heater from pallet unscrew the two coachscrews passing through the brackets into the wooden pallet, take out the two setscrews (one on each bracket) from the heater base, remove brackets. Ensure setscrews are replaced immediately in heater to properly support corner legs and base panel. NOTE: PAK-A-WAY U.H. Air Heaters are supplied suitable for firing on NATURAL GAS ONLY as standard. If units are required to be fired on an L.P .G. gas then they must be converted prior to installation with a suitable conversion set supplied loose and sent separately as an extra. For further information please contact the Package Heater Co. Limited Sales Office. (See this manual for information required), Heaters are supplied with a loose gas cock tied to the gas burner manifold inside the heater casing adjacent to the gas valve. An adaptor plate for converting the vertical flue socket spigot to horizontal outlet is also supplied loose attached to the wooden pallet. 10 WARRANTY Please refer to the 'Conditions of Sale' printed on the reverse side of the Sales Acknowledgment, copies of which can be supplied separately if requested from the Package Heater Co. Sales Office.
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Warranty is void if: (a) Installation is not in accordance with the Codes and Standards listed in Section 1B General Requirements of this manual. (b) The flue arrangement and air supply for the heater is not in accordance with the recommendation or codes of practice referred to in this manual. (c) Air through heater is not provided in accordance with the technical specifications on the heater data plate. (d) Internal wiring on heater has been modified ·by user, installer or service undertaken without PAK-A-WAY permission and/or written agreement. (e) Heater is o.perated in the presence of Chlorinated Vapours or corrosive atmospheres, e.g. degreasing plant, certain types of paint, acids or high salt concentrations. (f) The low voltage (24 volt) controls have been subjected to mains voltage. (g) The heater has been switched on and off via a timeswitch wired incorrectly, according to the wiring diagram supplied with this manual or heater wiring diagram. (h) The main electrical supply input to the air heater has been switched on and off by other methods to control heater, e.g. switched on and off via isolator or a plug. (j) Heater has been affected by the ingress of water in any form.
If a CLAIM UNDER WARRANTY is made then the following information is required to enable a replacement to be supplied: (j) Heater serial number (ii) Heater G.C. number (iii) Heater model
(This information, i.e. (i), (ii) and (iii) above, can be found on the Data plate affixed to the cover of the wiring box which is inside the service access panel of heater). (iv) Original order reference (where known) or approximate date of supply and full site address and installer's name and address. (v) Information and symptoms regarding the alleged fault. Warranty on heater parts is twelve months from date of delivery, unless a specific part is guaranteed for a longer period by the manufacturer, when the applicable extra period will apply. FAULTY PARTS MUST BE RETURNED TO THE PACKAGE HEATER CO. LIMITED, SALES OFFICE. ADDRESS AS LISTED INSIDE THE FRONT COVER OF THIS MANUAL FOR INSPECTION TO VERIFY THE CLAIM (UNLESS SPECIFICALLY REQUESTED TO BE SENT TO OUR WORKS). Note: Notification is required immediately a fault is suspected, otherwise no responsibility can be taken for further damage or expense incurred if other means are used to carry out. rectification works.
1EHEATER POSITIONING For best results, the air heater(s) should be placed with certain rules in mind. In general a heater should be located from 1.83 metres to 3.05 metres (6 to 10 feet) to the underside of base from factory floor level, according to size, to utilize the maximum effect of air throw. (Refer to Technical Data section elsewhere in this manual). The location chosen for the air heater must allow for the fitting of an effective flue system and provide adequate supply, return air circulation, gas supply, electrical supply and service access. clearance for ~ir I Suspended air heaters are most effective when located as close to the working area as possible and this fact should be kept in mind when determining the mounting height to be used. However, care should be exercised to avoid directing the discharged air directly onto the room occupants. Atthose points where infiltration of cold air is excessive, such as at entrance or loading doorways, it is desirable to locate the air heater so that it will discharge towards or preferably across the source of cold air from a distance of approximately 1.5 to 6 metres (5 to 20 feet) dependant upon doorway size and air throw of heater chosen. Air heaters should be arranged to discharge toward or along exposed wall surfaces, if possible. Where two or more units are employed in the same room, a general scheme of air circulation should be maintained for the best results.
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1F INSTALLATION CLEARANCES The air heater(s) must be installed taking into account the following minimum clearances to allow for safe installation from combustible surfaces and servicing: FRONT - 150 mm (6 inches) REAR - 600 mm (24 inches) from rearmost point of heater TOP - 600 mm (24 inches) LEFT - WIDTH OF HEATER - PLUS 300 mm (12 inches). Refer to Technical Data Section (for width dimension) elsewhere in this manual. RIGHT - 600 mm (24 inches) Note: When referring to left and right hand side of air heater it is assumed that the discharged air from the heater is blowing towards the face of the viewer. These distances apply to wall mounted or suspended air heater installations. Any combustible material adjacent to the air heater(s) and/or flue system(s) must be so placed or shielded as to ensure that its temperature does not exceed 65 deg. C. (150 deg. F.) 1G HEATER MOUNTING The air heater(s) must be installed so that they are level and rigidly fixed. All suspension and/or supporting materials must be non-combustible and capable of withstanding the effects of corrosion. The air heater(s) may be suspended from the eyebolts provided on top of heater cabinet, using chains, cables, straps or rods ensuring that all four suspension points fitted are utilized and the weight evenly distributed, or may be mounted supported on or from steel brackets. Alternatively the air heater may be positioned supported on a flat roof area such as over an office, storeroom etc. In this case they may be mounted on a non-combustible surface which is capable of adequately supporting the weight of the heater and any ancilliary equipment. Check the heater weight from information supplied in the Technical Data Section elsewhere in this manual. Attention should be paid to ensure full access is still retained for servicing, e.g. air heaters should not be fitted inside an angle iron frame which would prevent full service access and removal of burner tray. In particular that no hazard will be presented to personnel working below, or in the vicinity, or to personnel employed to carry out any service work on the air heater. Each of the provided eyebolts has a thread size of 8 mm, with an overall dia of eyebolt 36 mm and internal diameter of 20 mm. 1H WARM AIR DISTRIBUTION/CIRCULATION The temperature rise through the air heater is approximately 40 deg. C (72 deg. F). The air heater(s) should be positioned to enable maximum circulation of discharged warm air within the area to be heated whilst taking into account personnel in working areas, sources of cold air ingress and obstructions to circulation. Recommendations for the air distribution are given in the document entitled 'Standards of Installation for Gas Fired Industrial Warm Air Heaters' (published by the Industrial Warm Air Heater Manufacturers Association Limited). The following notes are of particular importance. A full and unobstructed return air path to the air heater(s) must be provided. Care must be taken when air heaters are used, to blow through wall openings, to ensure that return-air intakes are kept clear of sources of smells and fumes. In special circumstances where there is any possibility of pollution of the air by dust, shavings etc., precautions must be taken by carefully positioning return-air intakes from the area being heated. Where there is a risk of combustible material being placed close to the warm air outlets, suitable barrier rails should be provided to prevent any combustible material being within 910 mm (3 ft.) of the outlets. 1J AIR SUPPLY The following notes are intended to give general guidance. In all cases there must be provision for an adequate supply of air for both combustion and general ventilation.
6
Where the air heater(s) is to be installed in the space to be heated, the air heater(s) requires the space containing it to have a permanent air vent direct to outside air. The air vent should have negligible resistance and must 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. NOTE: If a PAK-A-WAY unit heater is installed in a room equipped with an air, dust, fume extraction system or a flue venter fan(s) fitted, then the permanent air vents must be sized to take this into account and allow for the required air changes. The basic minimum effective area requirement of the air vent is as follows:
TOTAL INPUT RATING OF AIR HEATER INSTALLATION
AI R VENT AREA (Air direct from outside)
Up to 730 kW (Up to 2,500,000 btu/hr)
4.5cm 2 per kW (1 in 2 per 5,000 btu/hr)
730 kW to 1320 kW (2,500,000 to 4,500,000 btu/hr)
3,300 cm 2 (500 in 2 )
Above 1;320 kW (Above 4,500,000 btu/hr)
2.5 cm 2 per kW (1 in 2 per 9,000 btu/hr)
NOTE The above requirements do not allow for any air extraction allowances.
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The air supply requirement stated above is related to the maximum rated heat input of the air heater installation.
7
AIR SUPPLY REQUIREMENTS FOR SINGLE HEATER INSTALLATIONS
LOW LEVEL RETURN AIR VENTILATION REQUIREMENTS
HEAT INPUT
FREE AREA OF VENT TO OUTSI DE AI R
* FREE AREA OF RETURN INTAKE AIR FOR CIRCULATION
HEATER MODEL
kW
Btu/h
cm 2
ins 2
cm 2
ins 2
UH100
38.1
129,900
171
27
18,840
2,300
UH140
53.3
181,800
239
37
20,440
3,168
UH180
68.5
233,800
311
48
26,000
4,030
UH240
91.3
311)00
410
64
35,2~0
5,470
UH320
121.8
415,600
549
85
46,450
7,200
Where two or more heaters are installed in the same room the aggregate input rating should be used for sizing the air vents. * NOTE: IT IS IMPORTANT THAT THESE AREAS ARE ADHERED TO PREVENTING NEGATIVE PRESSURES IN PLANT ROOM.
,----_____-11
R ETUR N AI R
1K FLUE INSTALLATION It is essential that the products of combustion be flued to the outside of the building. The air heater(s) must be installed with a flue range correctly sized and fitted with an approved flue terminal (the conical cap is not recommended), ensuring that care is taken to comply with all necessary regulations regarding flue height and materials used. (See BS5440 Part 1). If asbestos or spirally wound metal flue pipe is used then a suitable flue socket adaptor, which increases the size of the flue outlet accordingly, must be used. The Package Heater Co. Ltd. will generally be able to advise a recommended source from which these can be obtained. Note: Asbestos flue pipe is not recommended for suspended units and should only be used when the heater is rigidly supported. The following general recommendations apply to satisfactory flueing of the air heater(s). 1. All PAK-A-WAY U.H. air heaters are equipped with a built in down draught diverter which prevents the recirculation of combustion products. Conseauently an external draught diverter, barometric damper or antispiliage system must not be installed. All PAK-A-WAY U.H. air heaters are designed so that such devices are unnecess~ry. No internal alteration should be made to the built in down draught diverter. A minimum of 150 mm (6 ins) unobstructed clearance is required in front of the heater to allow for correct operation of the draught diverter. 2. If units are to be used to blow through a wall opening ensure at least 150 mm (6 ins.) clearance in front of the heater, to allow for the correct operation of the draught diverter. A stub duct should be positively fitted and sealed at connection to heater and around wall opening. Adequate return air facility must be provided. (See section 1J).
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3. The interchangeable flue outlet on the PAK-A-WAY U.H. air heaters can be fitted to provide a horizontal rear outlet, as required on site, instead of the vertical outlet which is fitted as standard. (Refer to technical data section for outlet positions supplied elsewhere in this manual). To change fitting: unscrew the flue socket plate from air heater, position the supplied adaptor plate with open end towards rear of heater and refit screws.Re-position the flue socket plate in horizontal outlet position and replace the fixing screws. 4. The vertical height of the flue, measured from the flue socket outlet of the air heater to the outside terminal, should be a minimum of 1.8 metres (6 ft.) in order to provide an adequate natural draught. The temperature of the products of combustion leaving the heater is approximately 260 deg. C (500 deg. F) hence they rise naturally in the flue; therefore unnecessary bends and obstructions should be avoided. If this is inapplicable, the installation of a flue venter fan should be considered which can be supplied by PAK-A-WAY (see separate section 1U in this manual for the fitting and wiring of flue venter fans). NOTE: If a flue venter fan is used the flue size from the venter is decreased. i.e. UH100 & UH140 4 ins dia (100 mm dial Flue UH180-UH24O-UH320 6 ins dia (150 mm dial Flue 5. Horizontal runs of flue should be ,avoided: wherever possible. A near horizontal run of 3 metres (10 ft) maximum should not be exceeded. A positive rise in the direction of the flue gasses to be evacuated, of 65 mm (2}'2 ins) per 300 mm (12 ins) of horizontal run is recommended. Where near horizontal flues are used, the vertical height must be a minimum of one and a half times the horizontal length. A ratio of twice vertical height to once horizontal length is more desirable. (If in any doubt on this please consult the PAK-A-WAY Sales Office - telephone number at the front of this manual). Flue pipes must not have sharp bends. Easy obtuse bends are necessary to assist the flow of gasses. 6. Allowance should be made for the disconnection .of the flue range(s) from the air heater(s) for inspection and servicing purposes. Where it is considered appropriate bends should be fitted with removable access covers for inspection and cleaning purposes. 7. The flue system(s) should ensure for the safe and efficient operation of the air heater(s) to which attached. Termination should be in a freely exposed position and must be so situated as to prevent the combustion process being affected by wind, allow for the dispersal of combustion products to open air, prevent the products of combustion entering any opening in a building in such concentration as to be prejudicial to health or a nuisance. 8. The flue pipe(s) should be connected to a permanent chimney or extended through a roof or wall and extend at least 1 metre (3 ft) above any obstruction within 3 metres (10 ft) of the outlet. IT IS IMPERATIVE THATWHERE'FLUE PASSES THROUGH ROOF, THIS OPENING IS PROPERLY SEALED BY A ROOF FLASHING PLATE AND CRAVAT TO ENSURE NO WATER ENTERS. NOTE: CLAIMS FOR ANY DAMAGE RESULTING FROM THE INGRESS OF WATER WILL NOT BE CONSIDERED. Combustion products contain water vapour which may condense out in the case of long or exposed flues. Prevention of condensation within the flue should be an important factor in the design of a flue system. Where a flue system is passing through an unheated area or is sited in an exposed position these sections may be fitted with a twin wall flue to minimise condensation. NOTE: If a twin wall flue is used it should be of a type acceptable to BRITISH GAS and a suitable adaptor(s) will be required. Where condensation in the flue is unavoidable, provision should be made for condensate to flow freely to a point at which it can be released, preferably into a gully. The condensate pipe from the flue to the dispersal point should be of non corrodible material of not less than 22 mm (3/4 in) diameter. 1L ELECTRICAL SUPPLY ALL ELECTRICAL WIRING AND CONNECTIONS MUST BE MADE IN ACCORDANCE WITH THE I.E.E. REGULATIONS. CHECK ANY LOCAL REGULATIONS THAT APPLY. WARNING: ENSURE THAT ELECTRICAL SUPPLY AND GAS SUPPLY ARE TURNED OFF BEFORE ANY WORK IS CARRIED OUT ON AIR HEATER TO CHECK WIRING. The main 240 volt and 24 volt control wiring must not be run within the same conduit, multi-core cable or mineral insulated Pyro cable. Voltage pick-up may occur leading to air heater malfunction and/ or permanent damage to the heater control system. The main electrical supply must not be switched OFF to the air heater, to stop it (allowing overheating to occur with subsequent damage to the air heater or controls), except in an emergency or when air heater has sufficiently cooled for servicing purposes.
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NO CLAIMS FOR ANY DAMAGE WILL BE CONSIDERED RESULTING FROM (a) INCORRECT WIRING OR OPERATION AS ABOVE (b) WHERE THE HEATER 24 VOLT CONTROLS HAVE BEEN SUBJECTED TO MAINS VOLTAGE. (I) Each air heater will require a permanent 220/240 volt 50 cycle electrical supply which must be wired through a 13 amp or 15 amp electrical fused isolator fitted with a fuse rated at 5 amps. The correct supply connection points for the live, neutral and earth are clearly indicated on the wirino diaaram mounted inside the wiring box cover olate fittp.rJ inside heater, being the first three terminals respectively from left to right numbered 1L, 2N and 3E (see wiring diagram supplied elsewhere in this manual).
(II) The isolator should be mounted adjacent to the air heater in an easily accessible position to allow for service isolation or emergency shut-off of electrical supply. (III) External wiring should be run in 1mm 2 insulated cable with a copper conductor (or equivalent) based upon a volt drop per ampere per metre of 40 mV.Total volt drop must not exceed 2.5% of the nominal voltage. Conduits should be positioned to ensure that they do not interfere· with service access to heater and be properly secured. ,Terminals 11 and 12 have been bridged to facilitate operation without a 24v thermostat. Terminals 5 and 6 have been bridged to allow operation without a timeswitch or a 240v thermostat. (IV) On no account should more than one air heater be connected to a single thermostat or timeswitch. N:B. The exception to this is when a control box (see note following) supplied by the Package Heater Co. Limited suitable for controlling one to four or five or six air heaters is employed. Then the air heaters must be wired in accordance with the multi-heater wiring diagram supplied with the control box, read in conjunction with the wiring diagram on air heater wiring box cover or supplied with this manual. ,
NOTE: The control box for use with multi-heater installations is not included in the British Gas Approval of this appliance. t
CARE MUST BE TAKEN TO ENSURE THAT ANY WIRING DOES NOT LIE AGAINST ANY METAL SURFACES LIKELY TO GET HOT CAUSING THE INSULATION TO BREAK DOWN, RESULTING IN SUBSEQUENT SHORT CIRCUITING CAUSING DAMAGE TO HEATER CONTROLS. 1M CONTROL PANEL [WIRING BOX] Remove the service access panel (refer to service section for details). Check the air heater DATA PLATE (fitted on wiring box ccver) to ensure that the su!)olv voltaqe and current requirements are correct. PAK-A-WAY heaters are fitted with a double wound transformer with a secondary output of 24 volt to supply the low voltage burner controls and gas control valve. Unscrew the two screws retaining wiring box cover and remove. Check all wiring connections for security, that no loose strands of cable wire are near or bridging across terminals. Ensure that all cables are clear and secured. Especially ensure that cables are not resting against back panel of wiring box adjacent to heat exchanger which can get hot from radiated heat. Check that the fitted 2 amp internal fuse is secure and is not blown or broken. Ensure that all external controls are wired up in accordance with the appropriate wiring diagrams. (See this manual and/or wiring diagrams supplied with controls). 1N TIME SWITCH Where fitted, if wired into the 24 volt circuit (i.e. across terminals 11 and 12) supplying the low voltage controls, must have separate motor and load connections. If a time switch is used having a common motor and load supply then it should be wired with the switched contacts operating across terminals 5 and 6 in the heate~ control panel wiring box (see wiring diagram supplied with this manual). The time switch manufacturer's instruction leaflet should be consulted and adjustment made for correct ON/OFF sequence, day omission and early off as required by client or user. 1P ROOM THERMOSTAT IF THERMOSTAT USED WITH THE AIR HEATER IS 24 VOLT AND IS FITTED WITH AN ANTICIPATOR, THE LOAD CURRENT RATING REQUIRES TO BE ADJUSTED TO A SETTING OF 0.3 AMPS, UNLESS A FLUE VENTER [SEE SECTION 1U]IS FITTED TO AIR HEATER WHEN A SETTING OF 0.425 AMPS MINIMUM IS REQUIRED. It must be wired in conjunction with the directions enclosed with thermostat and wiring diagram fitted in air heater or supplied with this manual. NOTE: 24 VOLT EXTERNAL WIRING MUST BE WIRED IN ACCORDANCE WITH I.E.E. REGULATIONS, SEPARATE FROM AND TO THE MAIN 240 VOLT WIRING.
10
1Q
ROOM THERMOSTAT SITING
The selection of the correct position for the room thermostat(s) is particularly important and should be sited at a point which will be generally representative of the heated area(s), as far as temperature is concerned. Draughty areas or areas subject to direct heat, e.g. from the sun, in direct line with air heater discharge, where air movement is relatively stagnant, such as recesses, are all positions to be avoided.
The thermostat should generally be mounted at a height of approximately 1.5 m (5 feet) from the floor.
1R FAN CONTROL SWITCH
The fan control switch (normally open 240 volt contacts) is wired to control the live supply to the fan motor(s). The
circuit is made and fan(s) switched on when the anticipator prewired from the low voltage 24 volt burner control circuit heats up and closes the fan switch 240 volt contacts. When the thermostat is satisfied or timeswitch shuts down burner, the fan is delayed from shutting down until the thermal switch has cooled sufficiently so as radiated and convected heat from the heater structure does not damage controls. The fan control switch provides the following:
1(a) Delay of fan operation preventing initial circulation of cold air.
(b) Fan operation as long as the unit is hot. 2. Additional safety by keeping the fan in operation in the event that the gas control valve fails to close when the thermostat is satisfied. To be sure that the fan(s) can continue to operate, the power supply to the air heater must not be interrupted except when servicing the air heater or in an emergency. If the user requires to turn the air heater off at night, then the gas valve circuit should be opened by a single pole switch, summer/winter switch or timeswitch wired in as per wiring diagram supplied with this manual. 1S
LIMIT CONTROL SWITCH
A non adjustable (normally closed contacts) high temperature limit switch is fitted pre-wired into the burner control 24
volt circuit which is set to open at an air temperature of 87 deg. C (189 deg. F). This will shut off the gas valve in the
event of fan motor failure or if the outlet air temperature should exceed safe limits.
One limit stat is fitted to the air heater(s) for each fan motor fitted, i.e. UH1()()-UH14O-UHl80 each have one only and
UH24O-UH320 have two fitted.
1T SUMMER/WINTER SWITCH [where fitted)
Summer/Winter switches can be supplied loose as an extra if required. This is a make or break switch with three
positions:
WINTER - for heating circuit, OFF, SUMMER for fan ventilation only.
It should be wired into the 240 volt control circuit as shown on the wiring diagram supplied with this manual, and as
follows:
Pole 1 - TERMINAL CONNECTIONS
A. Connections 2 and 4 are common. If timeswitch fitted then outlet side from switched connection should be wired to either terminal 2 or 4 on summer/winter switch. If no timeswitch is fitted then connection direct from terminal 5 in heater wiring box. B. WINTER POSITION: Terminal 1 (outlet) should be connected to terminal 6 in heater wiring box. (This controls the burner circuit). C: SUMMER POSITION: Terminal 3 (outlet) should be connected to terminal 4 in air heater wiring box. (This provides a live supply direct to the fan motor(s) overriding the fan control switch to provide ventilation only during the summer). 1U
FLUE VENTER
Note: The Flue Venter is not included in the British Gas Approval of this appliance.
11
Flue venters can be supplied loose as an extra if required. A flue venter may require to be fitted to provide extraction for the products of combustion where: a. Horizontal flue runs are being used. b. Flue resistance requires fan assistance. NOTE: When a venter is fitted the outlet flue diameter (from venter) internal diameter is reduced to the sizes shown below: UH100-UH140 - 4 ins dia (100 mm) Flue
UH180-UH240-UH320 - 6 ins dia (150 mm) Flue
An approved pattern flue terminal is required to be fitted at flue outlet external to the building.
MAXIMUM FLUE LENGTHS WITH VENTER FITTED UH100
=
(30 m)
100 ft
Flue dia
(100 mm)
4 ins
UH140
=
(23 m)
75 ft
Flue dia
(100 mm)
4 ins
UH180
=
(11 m)
35 ft
Flue dia
(150 mm)
6 ins
UH240
=
(26 m)
85 ft
Flue dia
(150 mm)
6 ins
UH320
=
(28 m)
92 ft
Flue dia
(150 mm)
6 ins
Reduce these lengths by the following amount for each fitting as fitted 1350 BEND
= less (1.5 m) 5ft = less (3 m)
10ft
G.L.C. Term inal = less (3 m)
10 ft
900 BEND
The venters are supplied loose, together w ith a flue socket reducing adaptor plate and a make up blanking plate, to suit the model of Unit Heater to which they are to be fitted. To fit a venter, unscrew the sheet metal screws holding flue socket plate, fitted at top rear of air heater and remove. Place the horizontal flue outlet adaptor plate (supplied loose with air heater) on top of air heater with open end at rear and replace screws to fix. Position the venter flue spigot adaptor plate onto the air heater with spigot facing rearwards and outlet horizontal, place the blanking plate in position to seal off the flue outlet and fix them in place with the provided sheet metal screws. The venter can now be fitted to the air heater. The venter inlet should be fitted directly onto the spigot adaptor plate outlet at rear .of the air heater. The outlet position from the venter can either be placed horizontally so that the flue will then pass out on the right hand side of heater, or placed to allow flue to rise vertically (see following diagram) and fixed in position. NOTE: The venter must not be fitted directly onto the top of air heater, as this can give rise to problems with overheating of the venter fan motor and wiring. NOTE: THE VENTER MUST ONLY BE FITTED SO THAT THE AXIS THROUGH MOTOR SHAFT IS IN A HORIZONTAL PLANE.
12
INCORRECT INSTALLATI ON
RECOMMENDED CORRECT INSTALLATION
CORRE CT I NSTALLATION
r~~
Venter spigot adaptor plate
I I I
Blanking plate
Horizontal flue outlet adaptor plate
(Venter fitted directly
to rear of heater) .
1V
VENTER WIRING
HEATER INTERNAL WIRING ALTERATIONS Refer to the wiring diagrams elsewhere in this manual.
When fitting venter to PAK-A-WAY U.H. Air Heater(s) the internal wiring must be altered as follows:
(a) The overtemp limit control switch lead(s) fitted into terminal 11 on the terminal strip inside wiring box should be connected into terminal 8 instead. (b) The terminal numbers in venter are wired to the corresponding numbered terminals in the heater wiring box. (c) If heater is to be fitted with a timeswitch then the switched contacts should be wired across terminals 5 and 6 in heater wiring box, i.e. the primary mains electrical Jive supply to transformer. (d) Thermostat where fitted, 24 volt stat with an adjustable load amperage setting for anticipator should be set at 0.425 amps minimum.
13
VENTER TERMINAL WIRING GUIDE HEATER TERMINAL
VENTER TERMINAL
240 volt
6
Live feed in 240 volt
6
Venter motor
2
Neutral
2
Supply
3
Earth
3
24 volt
11
Live feed in 24 volt
Gas control valve
*8
Live feed out 24 volt
8
Earth
9
Supply
9
11
IMPORTANT * changed from terminal 11. See previous head ing Heater I nternal Wiring Alterations paragraph (a)
PRE-INSTALLATION CHECK
The air flow switch (A) is a small, spring loaded switch normally in an off position until the actuating button under the hinge (8) is depressed to close the circuit. It returns to the off position when the button is released. A flat blade (e) hinged at the back of the button (8) crosses the button and is extended into the air stream of the venter. The venter fan is started via the thermostat circuit which energises a relay fitted in venter closing the 240 volt circuit to the venter motor. When the air fan reaches velocity, the air flow switch blade is pushed back against the button, closing the circuit to the gas valve solenoid. The air flow switch blade extends through an opening (D) in the connection box (where it is located) and is bent to a 90 deg. angle (E) and then extends into the fan housing through a 6 mm (1/4 inch) wide slot. The angle of the 90 deg. bend must be adjusted by bending backward or forward so that the switch can fully open or close. A definite 'click' is heard both when the switch opens and closes. In the open position (when the switch button is depressed) a full 0.8 mm (1/32 ins) clearance should be provided after the click is heard. If that is not the case, bend the blade back at the angle until proper clearance is provided. When the blade is released, the off 'click' must occur before the blade is fully returned to its rest position against the side of the slot in the fan housing.
14
1W GAS SUPPLY The local GAS REGION is responsible for supplying and installing the service pipets) and gasmeter(s). If a gas supply and/ or meter is not present then they must be consulted to ascertain the availability of an adequate supply of gas for the proposed installation. Where a gas supply and meter is present, then the existing meter should be checked, preferably by the GAS REGION, to ensure that the meter and service pipe is adequate to deal with the rate of gas supply required. At the planning stage of each installation the local GAS REGION should be consulted. They will advise as to the pressure of gas supply, recommended pipe sizes and allowable pressure drop for single and multi-heater installations. The gas pipework from the meter must be fitted and supported in accordance with CP331:3 and should be sized to produce the required gas volume to each air heater, so that at least the minimum inlet pressure (see this manual or air heater data plate) is obtained to the burner manifold inlet, to give the required burner running pressure. An approved gas jointing compound must be used. Pipework smaller than the air heater gas inlet connection size must not be fitted. Gas connection should be made to the air heater through the hole provided in air heater(s) top panel, which is vertically above the burner manifold inlet connection. The provided union fitted on burner manifold inlet connection should be left in its present position, internally within the air heater casing as it will be required as a separation point when removing the burner for service or maintenance. Each PAK-A-WAY air heater is supplied with a loose gas isolating cock (usually found tied to the burner manifold inside service panel on air heater). Care should be taken when fitting to use correctly sized spanners only, without undue force, to prevent the possibility of distortion with subsequent gas leakage. After fitting the gas cock, it s,",ould be opened and closed by hand to ensure that it operates freely. EACH AIR HEATER MUST BE FITTED WITH A GAS SUPPLY ISOLATING COCK AND A SUITABLE UNION MOUNTED OUTSIDE HEATER CASING, POSITIONED TO ENABLE SERVICE ACCESS. THE COCK TO BE UPSTREAM AND ADJACENT TO THE UNION WHICH IN TURN MUST BE UPSTREAM OF THE BURNER INLET. Check that the type of gas to be used is correct for the burner. NOTE: PAK-A-WAY U.H. HEATERS ARE ONLY SUPPLIED FITTED WITH INJECTORS SUITABLE FOR USE ON NATURAL GAS AS STANDARD. CONVERSION SETS FOR OTHER TYPES OF GAS ARE AVAILABLE FROM THE PACKAGE HEATER CO. LIMITED, SUPPLIED LOOSE AS AN EXTRA. CONVERSION OF AN AIR HEATER MUST ONLY BE UNDERTAKEN BY A COMPETENT PERSON. Individual dieformed corrosion resistant aluminised steel burners, with flared ports and stainless steel ribbons capable of operating on natural, manufactured and L.P.G. gases are employed in the air heaters. These burners have accurate machine formed parts to give controlled flame stability and operation on all gases without lifting or flashback. All burners are factory mounted in an assembly tray which permits all of the burners to be removed as a single unit for inspection and/or service/maintenance. Access to burners is from the control panel side of air heater, i.e. left hand service side of air heater taken when viewing air heater and air being discharged directly into viewer's face . Cross lighting of burners is by means of an· integral flash carryover system ignited from a permanent pilot. BEFORE FINAL CONNECTION TO AIR HEATER[S] GAS SUPPLY PIPES SHOULD BE TESTED FOR SOUNDNESS AND PURGED IN ACCORDANCE WITH CP331 :3.
1X OPERATION ON L.P.G. [LIQUID PETROLEUM GASES] Note: Firing on L.P.G. is not included in the British Gas Approval of this appliance. CONVERSION OF AN AIR HEATER MUST ONLY BE UNDERTAKEN BY A COMPETENT PERSON. Note 1. FOR APPLICATIONS USING AN L.P.G. GAS EACH AIR HEATER MUST BE CONVERTED PRIOR TO OPERATION AS AIR HEATERS ARE ONLY SUPPLIED AS STANDARD FITTED WITH BURNERS SUITABLE FOR OPERATION ON NATURAL GAS (SERIOUS DAMAGE AND/OR FIRE/EXPLOSION MAY RESULT IF THIS IS NOT CARRIED OUT).
15
Note 2. EACH AIR HEATER MUST BE FITTED WITH A SEPARATE SECOND STAGE GAS PRESSURE REGULATOR TO ENSURE CORRECT BURNER OPERATING PRESSURE AND TO PROTECT GAS VALVE FROM TOO HIGH AN INLET PRESSURE. (Regulators are normally obtainable from the supplier of the L.P.G. gas). Suitable burner conversion kits are available (supplied loose for fitting by others) from The Package Heater Co. Limited as an extra. When ordering burner conversion kits the following information must be supplied: 1. L.P.G. Gas type (i.e. Propane, butane or mixture type & ratio of L.P.G. gas to air). 2. Specific gravity of gas. 3. B.t.u. content or S.1. equivalent (i.e. calorific value). 4. U.H. model number of air heater. 5. Serial number of air heater and gas control valve make (as fitted if existing air heater being converted). 6. Quantity of kits required. N.B. The L.P.G. gas supplier will normally be able to provide details of items 1, 2 and 3. Burner conversion kits comprise the following parts: a. The required quantity of main burner injectors suitable for the type of gas being used and the heater model. b. A suitable pilot injector (and a carryover injector for older units where fitted). c. A governor blanking plate suitable for either Honeywell gas valve currently used. (This is fitted in place of the governor). Honeywell leaflet. d. Air shutter assembly. e. An L.,.P.G. conversion label showing required burner pressure setting and type of gas being used. (To be fitted on air heater data plate which is to be found on outside of wiring box cover plate in control side of air heater). Gas pipework for L.P.G. operation must be adequately sized to provide the required minimum inlet pressure to each air heater. NOTE: WARNING -It is imperative that an allowance must be made to prevent any accumulation of L.P.G. gas in the base of air heater. This can be done by removing conduit knockout in base panel of air heater or drilling a 25 mm (1 inch) dia hole in base panel. Where air heater is mounted on a non-combustible surface, e.g. flat roof, then holes should be drilled in base of side panels adjacent to base panel, ensuring that adequate allowance for ventilation is provided to disperse any gas spillage. 1Y FITTING BURNER CONVERSION SET [L.P.G.] 1. Refer to service section of this manual 'Burner Removal' on how to gain access to main injectors. 2. Change all main injectors, using a 13 mm A.F. spanner only. 3. Fit air shutter assembly to burner air entry cover plate. Ensure that air shutters are in fully open position. An adjusting screw is fitted on the end manifold bracket held by a lock nut which moves the shutters and adjusts all burners simultaneously. Turning the screw clockwise opens shutters and anti-clockwise closes shutters. 4. Dismantle the pilot jet by undoing the pilot gas tube nuts, one on pilot, one on gas valve. Remove pilot tube. Unscrew pilot jet holder from pilot assembly, change jet and refit pilot tube. To ensure nuts are not overtightened, screw up by hand then turn a further quarter turn with spanner. (Over tightening may cause gas leakage to occur). Similarly fit carryover injector where fitted. 5. Refit burner tray into air heater. (Refer as 1 above).
16
6. Remove the two retaining screws holding the domed gas governor on top of gas valve operator. Remove governor and neoprene gasket fitted to underside. Fit the cork gasket and then place metal blanking plate on top. Check to ensure dimple in blanking plate is facing upward. Refit the two retaining screws ensuring that they are evenly tightened (or as instruction leaflet supplied to suit gas control valve). 7. Check that conversion data plate is marked up for the correct type of gas to be used and that the burner setting pressure is correct. (Refer to following chart). Fit this on the heater data plate by removing the backing strip and position to cover the natural gas burner setting. N.B. It is recommended that the N.G. injectors and governor parts are placed in a suitable receptacle, clearly labelled and stored in heater casing or given to client for safe keeping in case they are required for future use. NOTE: Upon completion of installation and prior to commissioning, the gas pipework and associated regulators must be tested for gas soundness using a soap and water solution or other approved method . Naked flames must not be used. It is advisable to carry out a gas soundness check of gas control valve, burner manifold and burner pipework during commissioning with air heater running . If any leaks are found it is imperative that the gas supply is shut off and joints remade and then retested for soundness before installation is finally commissioned. COMMISSIONING L.P.G. FIRED AIR HEATERS 1. Commission air heater(s) as detailed in Section Three (elsewhere in this manual) and adjust the burner pressure on air heater(s) as below, or as directed on conversion label supplied with the conversion kit if gas is a mixture or differs from following pressure table. 2. Wait until.air heater has been in operation for at least fifteen minutes, release air shutter lock nut with a spanner and close air shutters until flame just goes yellow, then open shutter until the yellow tipping on burner flames just disappears. Re-tighten lock nut when adjustment completed. 1Z L.P.G. GAS PRESSURE SETTINGS
PRESSURE SETTINGS FOR L.P.G. GASES TYPE OF
LPG
BUTANE (CV 3270)
PROPANE (CV 2500) MINIMUM INLET PRESSURE
HEATER GAS VOLUME
BURNER PRESSURE
MINIMUM INLET PRESSURE
GAS VOLUME
BURNER PRESSURE
MODEL
ins
ins
ins
ins
m3/hr
CFH
mbar
W.g.
mbar
W.g.
m 3 /hr
CFH
mbar
w.g.
mbar
W.g.
UH100
1.5
52.0
41
16.5
35.5
14
1.1
39.7
32
13
27.9
11
UH140
2.1
72.7
41
16.5
35.5
14
1.6
55.6
32
13
27.9
11
UH180
2.6
93.5
41
16.5
35.5
14
2.0
71 .5
32
13
27.9
11
UH240
3.5
124.7
41
16.5
35.5
14
2.7
95.3
32
13
27.9
11
UH300
4.7
166.2
41
16.5
35.5
14
3.6
127.1
32
13
27.9
11
NOTE: INLET PRESSURES AS ABOVE ARE MINIMUM WITH ALL HEATERS RUNNING A SEPARATE GAS PRESSURE REGULATOR MUST BE INSTALLED TO EACH HEATER TO OBTAIN THESE FIGURES.
17
SECTION TWO· TECHNICAL DATA
THESE APPLIANCES ARE APPROVED BY BRITISH GAS FOR USE ON NATURAL GAS
Heat Input PAK-A-WAY UNIT HEATER kW MODEL
Btu/H
PRESSURE SETTINGS FOR NATURAL GAS Minimum (See Note 2) Inlet Heat Output Pressure Burner Pressure Gas Rate (see note 1)
kW
Btu/H
Gas Inlet Size
Minimum Nominal Flue Size (see note 5)
mm
m 3 /hr
Ft 3 /hr mbar
ins w.g.
mbar
ins W.g.
ins bsp
ins
UH 100
38.1
129,900 29.3 100,000
3.61
127
16.5
6.5
9.5
3.8
Y:.(RCY:.) 125
5
UH 140
53.3
181,800 41.0 140,000
5.05
178
16.5
6.5
9.5
3.8
Y:.(RCY:.) 150
6
UH 180
68.5
233,800
52.7 180,000
6.49
229
16.5
6.5
9.5
3.8
Y:.(RCY:.) 200
8
UH 240
91.3
311,700
70 .3 240,000
8.65
306
16.5
6.5
9.5
3.8
%(RC%) 200
8
UH 320
121.8 415,600
93 .7 320,000
11.54
407
16.5
6.5
9.5
3.8
%(RC%) 250
10
NOTE 1. Inlet pressure is to each heater and must be taken with all appliances working together.
NOTE 2. Burner pressure - This must be taken on the outlet side of gas valve fitted in burner manifold at the outlet pressure
tap. (See Technical Data section regarding Honeywell Gas Valves in this manual for indication of this position) . NOTE 3. Maximum inlet pressure not to exceed 50 .7 mbar (20 ins w.g.) NOT.E 4. Gas supply pipework must be free of internal scale and swarf. Where old gas pipework is utilized, a strainer should be fitted in gas pipeline adjacent to and on the inlet of each air heater. NOTE 5. Refer to Technical Data Section "Dimensions" for recommended sheet metal flue pipe sizes and to Section 1 K, for details on the use of asbestos and spirally wound metal flue pipes.
INJECTOR SIZE CHART NATURAL GAS at 9.5 m bar (3.8 insw .g.)
INJECTOR SIZES
HEATER MODEL
HEAT INPUT kW
Btu/h
Main burner injectors Number off per heater
PROPANE at 35.5 m bar (14 insw.g.)
BUTANE at27 .9mbar (11 ins w.g.)
Main burners
Pilot (twin hole)
Main burners
Pilot (twin hole)
Main burners
Pilot (twin hole)
mm
ins
mm
ins
mm
ins
UH 100
38.1
129,900
5
2.40
0,018
1.30
0.Dl0
1.30
0.010
UH 140
53.3
181,800
7
2.40
0.018
1.30
0.010
1.30
0.010
UH 180
68.5
233,800
9
2.40
0.018
1.30
0.010
1.30
0.010
UH 240
91.3
311,700
12
2.40
0,018
1.30
0.010
1.30
0.010
UH 320
121.8
415,600
16
2.40
0,018
1.30
0.010
1.30
0.010
GROSS IGNITION FROM PILOT TO MAIN BURNERS IS BY FLASH CARRY OVER SYSTEM
NOTE: These appliances are approved by BRITISH GAS for use on NATURAL GAS.
18
SECTION TWO - TECHNICAL DATA
PERFORMANCE DATA Model No.
UH 100
UH 140
UH 180
UH 240
UH 320.
Input
kW Btu/h
38.1 129,900
53.3 181,800
68.5 233,800
91.3 311,700
121.8
415,600
Output
kW Btu/h
29.3 100,000
41.0 140,000
52.7 180,000
70.3 240,000
93.7
320,000
m 3 /h CFM
2,160
3,030
3,890
1,271
1,783
2,289
5,190 3,054
CAPACITY
AIR FLOW
THROW (AVERAGE, FREE AIR)
6,920 4,072
m
14
17
20
24
28
ft
46
56
66
79
92
MOTOR
HP
1/6
1/6
1/6
ELECTRICAL RATING
WATTS
ELECTRICAL RATING
AMPS
180 .75
200
235
400
470
.83
1.0
1.66
2.0
I
t
--r
C/l-Horizontal Flue
(1) Electrical conduit entry point (2) Gas supp'y entry point
W
X
C
t
I
I ? ' -....
2 x 1/6
2 x 1/6
-_~-rr
I
_
21 %" 552
~1
_
~--~------~-~~ I D
t
E
19%" 500
T
•
t,-----+----.'I--1 (1 )
lower access panel
---''---------- - t;;;;;;;;;;;;;;;;;;;;;;:;::~~:;;;;;;;;;;;;;;;11 __
~_-,-
DIMENSIONS (lNS/MM)
AND WEIGHTS
Model No. A 8 C D E
J P S T V W X Y Z
Width Height length Front opening/top Front opening Eyebolts Ctrs . Flue C/l to back Recommended sheet metal flue size Horizontal flue C/l from base of heater Flue socket internal diameter Height of Horizontal flue adaptor plate Hor. Flue C/l to top of adaptor plate length of Horizontal flue adaptor plate Width of Horizontal flue adaptor plate
UH 140
UH 100 22 32.1/4 36 5 .1/2 17 16.3/8 3.1/4 6 32.5/8 6.1 3.5/8 3.1/4 5.5/8 10.1/2
Service access and
Co nt ro I Pane' (W i ri ng Bo x) Top view
side
EYE80l T SIZE M 8 36mm OlD 20mm I/D
- 557 - 819 - 911 -138 - 431 - 416 82 - 150 - 829 -155 92 82 - 143 - 267
27.1/2 32.1/4 37 5.1/2 22 .1/2 21 .3/4 3.5/8 7 32.1/4 7.1 3 .5/8 3 .5/8 5.5/8 10.1/2
UH 180 - 697 - 819 -940 - 138 - 571 - 552 92 -175 - 819 - 181 92 92 -143 - 267
33 35.1/4 38.1/2 8.1/2 28 27.1/4 5 8 34.3/4 8.2 4.1/2 5 8.3/4 15.1/2
- 837 - 895 -980 - 214 - 711 - 692 - 127 - 200 -883 - 207 - 114 - 127 - 222 - 394
UH 240
UH320
41.1/4 -1046 35.1/4 895 36 911 8.1/2 214 36.1/4 921 35.1/2 902 - 127 5 200 8 34.3/4 883 207 8.2 4.1/2 114 127 5 - 222 8.3/4 394 15.1/2
52.1/4 -1326
35.1/4 - 895
38.1/2 980
8 .1/2 214
47.1/4 - 1201
46.1/4 - 1181
5 127
10 250
34.3/4 883
10.2 258
4 .1/2 114
127
5 8.3/4 222
15.1/2 394
3/4
3/4
-
GAS CONNECTION SIZE (ins. 8.s.p.)
1/2
Net weight lb/kg (Approx.l
192
87
207
94
260
- 118
321
-146
422
-192
Shipping Weight lb/kg (Approx .)
209
95
224
- 104
282
- 128
348
-158
454
- 206
1/2
1/2
Models and Data: subject to modification without prior notice. The Package Heater Company, whose policy is one of continuous development and improvement, reserve the right to alter any specification appearing in this manual without notification. 19
A
SECTION TWO - TECHNICAL OAT A
AIR HEATER MOUNTING HEIGHTS Heater model
Metres
Feet
Minimum
Maximum
Minimum
UH100
1.83
2.44
6
8
UH140
1.83
2.44
~
8
UH180
2.13
2.74
7
9
UH240
2.13
3.05
7
10
UH320
2.13
3.05
7
10
Maximum
NOTE: CARE SHOULD BE TAKEN WHEN MOUNTING AIR HEATER(S) AT MINIMUM HEIGHT THAT OBSTRUCTION OR DANGER IS NOT CAUSED TO PERSONS WORKING IN THE VICINITY.
THERMO-ELECTRIC GAS COMBINATION VALVE
Heater Model
Honeywell Gas valve Type
Honeywell 24 volt Solenoid
Inlet Thread Size
Outlet Thread Size
Operator type
ins BSP
ins BSP
Type
Thermocouple Length Minimum
UH 100
V8600A
V804A 24V
% (RC%)
(RC%) % adapted
Bulex
300mm (12 ins)
UH 140
V8600A
V804A 24V
% (RC%)
(RC%) % adapted
Bulex
300mm (12 ins)
UH 180
V8600A
V804A 24V
% (RC%)
(RC%) % adapted
Bulex
300mm (12 ins)
UH 240
V8800A
V804A 24V
% (RC%)
%
(RC%)
Bulex
300mm (12 ins)
UH 320
V8800A
V804A 24V
% (RC%)
%
(RC%)
Bulex
300mm (12 ins)
USED ON l.jH100-UH140-UH180
V8600A HONEYWELL.GAS VALVE
OPERATION The operation of the pilot system is accomplished by manipulation of a single knob, which contains programme symbols that indicate the lighting and shut-off procedures. V8800A HONEYWELL GAS VALVE
USED ON UH240-UH320
OPERATION The operation of the pilot stat is by use of two push buttons; START button marked with a white flame, OFF button marked with a red spot.
20
SECTION TWO - TECHNICAL DATA
GAS VALVE DETAILS
SERVO-PRESSURE SINGLE ACT IO N PUSH-BUTTON
REGULAT O R ADJ UNDER CO VEA
MA IN VAL VE OPERAT O R
9-13mm (3/8"-1/2")
Gas Outlet
.-
thermocouple
INLET. PRESSURE TAP
O UT LE T PRES SU RE TAP
maximum temp. at thermocouple tip : 760 0 C temperature for optimum thermocouple life: 6500 C (A dull red colour)
PILO T FL OW AD J U ST M E NT
PILOT FLAME ADJUSTMENT The pilot flame should envelop 9 to 13 mm (3/8" to 1/2") of the thermocouple tip. Flow rate can be adjusted by means of the self-sealing pilot adjustment screw on top of the control. To decrease pilot flame turn clock wise . To increase pilot flame turn anti-clockwise .
INLE T PRESSURE
TAP
P ILOT
CON NECTi ON OUT LET
THERMOCOUPLE CONNECTION
P RE SS U ~E
TA P
FLANGE M OU N T ING
HOLES
The thermocouple connection at the valve is an electrical co,mection and must be clean and dry . Never use thread compound on this connection. Tighten 1/4 turn beyond finger tight for good electrical continuity . THERMO CO UPLE CO NNECT IO N
V8600 ADJUSTMENT POINTS AND MAIN FEATURES USED ON MODELS UH100 - UH140 - UH180
COV ER
PRESSURE REGULATOR
SCREW
ADJUSTMENT
_
START
BUTTON
.. ..
---'
LlJ---.li.-_ _~ /
THERMOCO UPLE
CONNECTION
__ _ Servo Pressure Regulator _ _ Main Valve Operator Pilot Outlet
PILOT FLOW ADJUSTMENT
PLUGGED OU TLET PRESSURE TAP 11\- BSPT
VI EW FROM UNDERSI DE OF- VAL V E
V8800 ADJUSTMENT POINTS AND MAIN FEATURES USED ON MODELS UH240 - UH320
21
SECTION THREE
COMMISSIONING INSTRUCTIONS
NOTE: PRIOR TO COMMISSIONING THE INSTALLATION INSTRUCTIONS SHOULD BE READ THROUGH AND REFERRED TO WHILST CARRYING OUT THE COMMISSIONING PROCEDURE. 3A ELECTRICAL INSTALLATION (General) Checks must be made to ensure that installation is safe and complies with I.E.E. Regulations. These tests should be carried out by a competent person. Particular attention should be made to ensure that thermostat, if other than that supplied by PAK-A-WAY, is suitable and that any 24 volt wiring is kept separated from the main 240 volt wiring to avoid damage to air heater controls or heater malfunction due to voltage pick-up. 3B GAS INSTALLATION (General) The whole of the gas installation should be inspected and tested for soundness and purged in accordance with the recommendations of CP331 :3. Any leaks must be rectified prior to commissioning and attention should be paid to ensure that any jointing compounds or materials used for jointing are of a recommended type. Where a new gas meter is installed or additional pipework added where a gas meter exists then the meter should be inspected and tested for soundness and purged in accordance with CP331:3 by the GAS REGION or its approved engineers under the Gas Region's instructions. An allowance for suitable gas isolating cocks and purging points should be made when designing and installing the pipework to enable the above work to be carried out without undue inconvenience. 3C GENERAL INSTALLATION CHECKS TO BE CARRIED OUT PRIOR TO COMMISSIONING IMPORTANT: Ensure gas and electrical supplies to the air heater(s) are turned off before carrying out any work to check installation. (a) The installation should be checked to ensure that the installation work has been carried out in accordance with the design requirements. (b) Check that air heater is mounted safely and securely and that all mounting brackets (where fitted), assembly screws and air heater panels are secure and in place. (c) Check flue installation is correct and secure and free from corrosion, that joints are sound and secure, that where required suitable support brackets are fitted correctly. Ensure that roof flue seal(s) (where applicable) are properly fitted and are watertight. Check that flue terminal is of approved type. (d) Check that air outlet louvre blades are undamaged, capable of being adjusted properly and that they are all opeh so as not to restrict air flow through the air heater(s). (e) Check fans to ensure that they rotate freely within the inlet orifice plate. Check that the fan blade is positioned inside the orifice plate to ensure correct air throughput. 3 mm (0.118 ins) of motor shaft should protrude through fan hub. Check that fan(s) are securely fitted on motor drive shafts, that mountings are secured correctly and that all fan guards are secured into their correct position. 3D LIGHTING THE AIR HEATER - PILOT COMMISSIONING WARNING: IF THE PILOT LIGHT IS EXTINGUISHED EITHER INTENTIONALLY OR UNINTENTIONALLY, NO ATTEMPT SHOULD BE MADE TO RELIGHT THE GAS UNTIL AT LEAST THREE MINUTES HAVE ELAPSED. 1. Switch OFF main electrical supply to the heater. 2. Set room thermostat to OFF or its lowest setting. If required set timeswitch to an ON cycle period. 3. Turn ON the main gas supply to the air heater. Open lower service access panel on air heater to gain access to gas valve. 4. Fit pressure gauge (manometer) to the pressure test nipple fitted on burner mainifold (on outlet side of gas valve).
22
5. Press in fully the start button on the gas control valve (Models UH100-UH140-UH180) or the white button (Models UH240-UH320) and at the same time apply a lighted match or taper to the pilot burner, accessible through mica window. (See Fig 1 & 2 Section 3M). 6. Once the pilot is alight, continue to keep the button fully depressed for at least 20 seconds before releasing. IMPORTANT: If the pilot flame goes out turn the start button (Models UH100-UH140-UH180) clockwise about a quarter turn, wait three minutes, then repeat from step (5). For Models UH240-UH320 push in the red stop button, wait three minutes, then repeat from step (5). 7. With the pilot flame established, replace the mica window. 8. Check pilot flame (see gas valve data section) and adjust pilot gas pressure if required. 9. Switch ON the main electrical supply to the air heater. 10. Adjust room thermostat to maximum temperature setting and main burners will light. (Note: After approximately one minute the air fan(s) will operate and stay on until the thermostat is satisfied, then they will operate according to demand from the thermostat). 3E MAIN BURNER COMMISSIONING 11. With main burner on, test for gas soundness around gas valve and burner manifold using sense of smell and soap and water solution. 12. After air heater has been alight for five minutes adjust the main burner gas pressure using the fitted manometer (see step 4) to (9.5 m bar) (3.8 ins w.g.) NATURAL GAS ONLY or as specified on the heater data plate if required to suit site conditions and type of gas being used. (Refer to gas pressure charts elsewhere in this manual). If the burner pressure requires adjusting refer to Honeywell Valve literature elsewhere in this manual for the position of the main pressure adjustment screw applicable to the air heater model. NOTE: Prior to crating the correct pressure setting has been made at the factory to suit the air heater model based upon burner pressure setting, when running of 9.5 mbar (3.8 ins w .g.) fired on Natural Gas only. Check input to main burners by timing the meter and reading off the consumption during timed period. Connect a pressure gauge (manometer) to the downstream pressure tapping (refer to Honeywell literature elsewhere in this manual for outlet pressure points relevant to the gas valve fitted on applicable air heater model). If adjustment is required, remove pressure regulator cap screw. Using a small broad screwdriver, turn adjusting screw clockwise to increase, or anticlockwise to decrease gas pressure to burners until correct pressure setting is achieved with burner running. NOTE: Adjustment fitting is plastic and may require slightly greater turning force than metal thread. Check each air heater in turn if more than one installed and then with all air heaters running recheck pressure. (Refer to gas pressure charts elsewhere in this manual applicable to the type of gas being used. Re-adjust as required). CAUTION: When using the meter to determine gas consumption on air heater(s) ensure that there is no gas flow through the meter, other than to the appliance(s) being checked. Other appliances must remain off and the pilots extinguished (or their consumption deducted from the meter reading). DO NOT EXCEED THE RATED INPUT OR MAXIMUM INLET PRESSURE TO EACH AIR HEATER. DAMAGE TO THE AIR HEATER OR ITS CONTROLS MAY RESULT IF THESE ARE EXCEEDED . 13. With burner set at correct operating pressure check the burner flame in order to establish that there is an adequate supply of combustion air. This can be done visually through the pilot lighting port window assisted by a burner flame inspection mirror. Correct burning is recognised when a clear conical blue flame is seen to be burning evenly along length of burner rail. If flame is seen to be yellow and uneven, then the combustion air inlets must be checked for obstruction (both side panels of heater), flue checked for downdraught, and area where heater positioned checked for negative pressure. If stub duct is fitted check that seal between duct and heater is sound and that positive allowance for return air has been made. (See Section One of this manual) . 14. Check to ensure that there is no spillage of products of combustion from the downdraught divertor by introducing smoke or a lighted taper close to the venting area at top front of air heater. If spillage is present the smoke will blow back out of air heater front or taper flame will flicker and decrease or extinguish. If spillage found it must be investigated and corrected.
23
3F TESTING THE AIR HEATER 15. Check operation of flame failure on the air heater to ensure that the main burners will shut down within ten seconds (flame failure on the air heater is controlled by a thermocouple mounted in the pilot flame which when lit heats the tip producing a small electric current to flow which in turn activates the electro magnet holding the gas valve solenoid open. When flame is extinguished the tip cools and no current flows; subsequently the valve will close and main burners shut down). To test, simulate flame failure by loosening the gland nut that secures the thermocouple to the gas control valve. When contact is broken, no gas should pass through the valve to the main burners or pilot. Ensure when replacing gland nut that it is not overtightened. (Refer to gas valve technical data elsewhere in this manual). 16. Check operation of heater limit switch(s) to ensure that they are able to function. (The over temperature limit switches, one in UH100-UH14O-UH180 and two in UH24O-UH320, are supplied to operate when the air temperature within the heater exceeds a preset limit - generally 87 deg. C (189 deg . F) - when the switch will open, breaking the low voltage 24 volt burner circuit through gas control valve, thus shutting off main burners). To test, simulate fan failure by blocking off the warm air outlets to the heater. This will cause the temperature within the air heater to rise and should shut down the main burners in approximately one minute. It should be noted that the limit switch is of the automatic re-set type, and continual cycling of the burner will occur if it is brought into use by fan failure when the timeswitch is in an on period and the thermostat is calling for heat. 17. Check ON / OFF operation of thermostat by manually turning temperature setting up or down when burner should be alight or shut-off. NOTE: Check that 24 volt thermostat with an anticipator (if fitted) is set to the correct current rating (see wiring diagram in this manual) and that the manufacturer's specified current rating is not exceeded. 18. Set timeswitch and/or thermostat to suit client's normal working times and days and temperature requirements. 19. Upon completion of the commissioning check that all air heater(s) casing panels/covers etc. are replaced and that all assembly screws are in place and secured. 20. After setting up the air heater(s) correctly, the full operation cycle on each unit should then be observed to ensure that it is functioning correctly. 3G PAK-A-WAY U.H. AIR HEATER OPERATION CYCLE With the main electrical and gas supplies on, pilot lit, timeswitch in an ON period and thermostat calling for heat (if fitted, Summer/Winter or heater switch must be in Winter or ON position) 1. The gas valve solenoid coil (24 volt) will be energised, opening gas valve, and the main burners will be ignited from the pilot via the flash carryover system. 2. At the ~ame time, a 24 volt supply passes to the anticipator fitted on the Fan Switch which begins to heat up. When sufficiently heated (after approximately one minute) it makes the connection within the fan switch allowing a 240 volt supply to pass to the fan motor(s) which then start up and warm air is discharged from the heater. 3. After a further period when the area to be heated is up to the thermostat temperature setting, the thermostat, being satisfied, opens and breaks the circuit to the gas valve, shutting off the gas supply to the main burners, which shut down. The main fan will continue to run until the air heater has cooled sufficiently. 4. The above four steps will then repeat until the ambient temperature rises above thermostat heat setting, thermostat is turned down to lower setting than ambient, timeswitch shuts off, Summer/Winter or heater switch (where fitted) are turned off, when Step 3 will repeat until the air heater has cooled down. NOTE: If the air heater gets too hot due to restriction of air throughput or flueing problems then the over temperature limit switch(s) will open, breaking the electrical circuit to the gas control valve to shut off the main burners. This cycle will repeat according to demand from the thermostat or until the timeswitch reaches an OFF period, when the burner will be shut down. The main fan(s) will continue to operate until the air heater has cooled down. 3H GAS CONTROL VALVE WARNING: In conditions of incorrect installation spillage of combustion products from the burner may occur. This can cause gross overheating of the gas control valve and wiring box, and may result in se'rious damage and an unsafe condition may take place due to the gas valve operator becoming locked in the open position, regardless of the function of the overheat limit switch. If this condition is noticed, the following steps should be taken: (a) Shut off gas supply to air heater via the air heater isolating gas cock. If this is not possible then the nearest gas isolating cock on the gas pipework supplying the heater should be shut off. Leave electrical supply on to the air heater (unless a fire hazard is present).
24
(b) The air heater should then be left to cool. The main fan will continue to operate until the unit has cooled sufficiently. (c) After allowing at least fifteen minutes from when main fan(s) has stopped then the air heater must be isolated from the gas and electrical supplies via its own electrical isolator and gas cock fitted on heater inlet. (d) The air heater must not be used again until a competent person has checked over and carried out any necessary repair works to ensure safe operation. (e) If any other appliances have to be shut down due to the main gas supply being shut off then they will require to be relit or recommissioned when the gas supply is restored, by a competent person. 3J AIR DISTRIBUTION - ADJUSTMENT The adjustable louvre blades fitted to each air heater should be adjusted so that the discharged warm air is directed toward the area to be heated in relation to the heater mounting height, air throw and general circulation scheme.
3K USER'S INSTRUCTIONS - ADVICE TO USER Upon satisfactory completion of the commissioning and testing of the installation, hand the 'User's Instructions' to the user. Explain and where required demonstrate the method of economic and efficient operation of the system. Ensure that the user is fully conversant with the lighting, shutdown and general operational procedures. Bring to the attention of the user the labels on the air heater, carrying instructions for lighting and the safe use of the heater. Where applicable, advise of the precautions necessary to prevent damage to the building and contents of the building in the event of the system remaining inoperative during frost conditions.
3L SERVICING & SPARES - ADVICE TO USER Advise the user or purchaser that for efficient and safe operation of the air heater(s), it is important that adequate servicing is carried out at regular intervals or as recommended by the local gas region. The installer should recommend a list of spare parts to be kept by the user or purchaser, particularly where the air heater(s) is an essential part of any system and its being out of operation may cause problems, for example by frost damage to stock. The installer should leave attached to the air heater(s) on a permanent card(s): 1. The date of installation and 2. The name and address of the installer.
NOTE: LEAVE INSTALLATION AND SERVICE INSTRUCTIONS WITH THE PURCHASER OR THE SERVICE ENGINEER. 3M GENERAL LIGHTING INSTRUCTIONS STARTING THE AIR HEATER Before starting the air heater ensure that all warm air louvres and ducting grilles,.if fitted, are open. Locate the pilot burner and gas control valve which are situated behind the bottom hinged lower access panel on the left hand side of the air heater. The pilot burner is directly behind the lighting port window (figs 1 or 2).
25
Fig.1. Lighting Instructions
UH100 - UH140 - UH180
Fig. 2. Lighting Instructions UH240 - UH320
LIGHTING AND OPERATING INSTRUCTIONS WARNING: If the pilot light is extinguished either intentionally or unintentionally no attempt should be made to relight the gas until at least three minutes have elapsed. TO START THE AIR HEATER a. Switch OFF the electricity supply to the heater. b. Set room thermostat to OFF or its LOWEST setting. If fitted, ensure time switch is set to an ON cycle. c. Ensure that the main gas supply to the air heater is on. d. Press in fully the start button on the gas control valve. (Models UH100-UH140-UH 180) or the white button (Models UH240-UH320) and at the same time apply a lighted match or taper to the pilot burner, accessible through mica window. (See Figs 1 or 2, as above). e. Once the pilot is alight, continue to keep the button fully depressed for at least 20 seconds before releasing. IMPORTANT: If the pilot flame goes out turn the start button (Models UH100-UH140-UH180) clockwise about a quarter turn, wait three minutes then repeat from step (d). For Models UH240-UH320 push in the red stop button, wait three minutes, then repeat from step (d). f. With the pilot flame established replace the mica window and burner compartment access panel. g. Switch ON the main electrical supply to the heater. h. Adjust room thermostat to desired temperature or switch on control switch as applicable, and main burner will light. TO STOP THE AIR HEATER For short periods Adjust the room thermostat to lowest setting or OFF, or if fitted switch off the manual control switch . The air heater will remain ready for use immediately ti,ese controls are readjusted. For long periods [e.g. Summer shutdown] a. Switch OFF control switch and turn down room thermostat to OFF or LOWEST SETTING. b. Turn the start button on the gas control valve for Models UH100-UH140-UH180 clockwise about a quarter turn. For Models UH240-UH320 push in the red stop button on the gas control valve. This shuts down the gas supply to the main and pilot burners. c. Wait fifteen minutes after air fans have stopped (to ensure heater sufficiently cooled) then switch OFF the main electricity supply to the air heater, and the gas supply using the externally located gas tap.
26
SECTION FOUR
AIR HEATER SERVICING
4A GENERAL IMPORTANT: Personnel engaged to carry out servicing and maintenance work on the air heater(s) must ensure, in the interest of safety, that the work is carried out in a competent manner, that no hazard exists to yourself and other personnel who may be working or present in the vicinity, i.e. injuries sustained from falling heater components, tools, bare electrical wires, etc. A clear access to the air heater(s) will be required and if needed a safe working platform must be available to comply with the requirement of the Health and Safety at Work Act 1974. The work should be carried out in a clean, comfortable manner, preferably in sequence against a check list to ensure that all necessary work is completed. Always ensure that due regard is paid to persons, property and contents of the premises you are working in. All accidents must be reported to the customer or customer's representative and to your employer. PAK-A-WAY U.H. air heaters require regular maintenance to ensure efficient operation and to reduce the risk of air heater breakdown. Periods between service are dependent upon the local conditions under which the air heater is operating. Regular inspection is recommended, initially to ascertain routine service intervals and under changing local environmental conditions consideration should be given to the interval between services. Generally the air heaters should be serviced at least once annually, preferably during the Summer when the air heater is not in use. 48 WARNING Prior to starting any service or maintenance work on the air heater, turn OFF the main gas supply to the heater at the service tap. Then when the air circulating fan has cooled the air heater down and stopped (wait fifteen minutes from when the fan(s) stops) switch OFF the main electrical supply to the air heater and remove fuses.
NOTE: The unit is not isolated electrically until the main isolator is switched off and the fuses removed. Switching off at the heater switch or thermostat is not suffiGient when work is being carried out on the air heater. Maintenance and service must only be carried out by competent persons. Where necessary reference should be made to the relevant separate instructions elsewhere in this manual. Refer to illustrations provided for indications of component location as a guide to removal and assembly. Ensure that all screws etc. removed are retained safely for refitting upon replacement of panels or parts etc. The heater model and serial number will be found on the heater data plate mounted on wiring panel cover plate. 4C SERVICE INSTRUCTIONS Items that require inspection and attention during servicing are as follows: Ensure that air heater is secure on supports and in correct position. Heater - check casing and panels for any distortion, damage or corrosion. Remove service side panel by unscrewing the two fixing screws located just below top on either side of panel, loosen the two setscrews located at bottom corners of panel holding heater casing (where fitted), lift panel up, slightly pull out bottom of panel to clear base of heater, drop panel down till clear of heater top and pull away. Remove wiring box panel cover by unscrewing the two fixing screws. Remove fan as an assembly, by disconnecting the fan motor wires from inside the wiring panel, gently pull out cable from wiring panel, then feed out through heater panel till clear, ensuring cable insulation is not damaged. Undo the four setscrews holding each fan assembly to heater back panel (ensuring that fan is fully supported) and pull away horizontally until fan clear of heater and casing. NOTE: Care must be taken when removing or replacing the fan to ensure that fan blade is not bent or damaged. The fan is a precision engineered and accurately balanced component. Do not bend, damage in any way, remove or reposition the balance tabs as this will disturb the balance and can cause damage to the motor(s) or heater and render the air heater noisy in use.
27
Remove burner tray as an assembly. Disconnect the two electrical leads to the gas control valve, uncouple the gas manifold union fitted on inlet side of gas valve (which should be fitted inside heater casing). Unscrew the two fixing setscrews, one left hand, one right hand in top corners of burner drawer assembly. Pull burner tray drawer out horizontally from service side of heater. Care should be taken to ensure that burner tray drawer weight can be fully supported if required to be fully removed. Check flue for blockages, corrosion and leaking joints (particularly at roof seal, where fitted). Ensure that any support brackets or bends (where fitted), cravats and terminals are in position, secure and free from corrosion. Inspect down draught diverter on heater and clean as necessary. NOTE: If a flue venter is fitted to heater(s) then pay particular care in cleaning the sail switch and in checking that it functions correctly. Do not oil the switch. Heat exchanger - (Ensure main burner tray drawer has been removed first). Clean external sections and where possible internal sections with a flexible flue brush from top and bottom. Remove loosened deposits with a suitable vacuum cleaner. If difficulty is found with the cleaning then the draught hood collector box can be removed to allow better access to the heat exchanger from the top. To remove, unscrew the sheet metal screws from the bottom front edge of collector box flange over the louvred outlet front panel. Grasp collector box front through the vent slot, raise, and pull forward horizontally out from the downdraught diverter front relief opening. If heat exchanger is found to be badly blocked which normal brushing will not clear then the air heater will require to be taken down and placed in a safe position to enable the draught hood assembly and base panel to be removed. This will then allow access to the interior of the heat exchanger to clean out internal built up deposits. NOTE: If this work is required, which is not part of a normal service, then the heater installation should be checked to ascertain the reason for this occurrence. Inspect the heat exchanger where visible inside and outside with the fan and burners removed and where able through the air discharge louvres. Look for signs of severe corrosion, splits and perforations that would indicate a failure. This is best done with the use of an inspection lamp and mirror. NOTE: If heat exchanger is found to be perforated advise user not to operate heater until a replacement has been fitted. Check that combustion airways into air heater are clean and free from dirt and grease. Check burner ribbons and clean if required any blocked parts with a brush or thin piece of sheet metal (preferably brass) or wood, drawing same along each burner slot, taking care not to damage or distort burner ribbons. Remove air entry cover plate from burner manifold. Unscrew the four retaining screws (UH100-UH140-UH180) or six (UH240-UH320) to expose the burner injectors. Check gas injectors for cleanliness and tightness. If required clean with acetone. Do not overtighten. NOTE: The orifice of a gas injector is machined to precision limits. Do not clean with a hard sharp object that could damage or enlarge the size. Remove carefully (use a 13 mm A/F spanner only). Remove pilot burner and thermocouple, clean including pilot burner gas supply pipe, examine thermocouple for damage, then re-assemble. Check that interior of heater casing is clean and then slide burner tray drawer back into heater and replace the two fixing screws. Reconnect the inlet gas manifold union to the supply pipe and refit the electrical leads onto gas control valve. Ensure that all manifold and supply pipe gas joints are sound and that gas control valve is visually in good condition. Carefully clean the fan motor(s), fan guard(s) and fan blade(s) to remove any accumulation of dirt and grease. Check that fan motor mountings are secure. Ensure fan shaft(s) are clean and that fan(s) are tight and that locking screw is correctly located on flat of motor shaft(s). Replace fan assemblies onto heater. Replace and tighten the four locating screws, refit electrical cable into heater wiring panel and reconnect electrical connections. Check and rotate fan by hand to ensure that it turns freely and does not impinge on air heater casing or any obstruction. Fan motor bearings are life sealed; no lubrication is necessary. Check all visible wiring for damage and conduits for chafing and security. Check terminal wire grips for tightness, ensure that no strands of electrical conductors are loose and liable to lead to short circuiting. Replace as required. Check condition of transformer. Look for any signs of overheating and short circuiting. Check earth continuity.
28
Remove fan control and limit control switches, clean and replace. Replace wiring panel cover plate.
Visually inspect main gas supply pipe to air heater for security and corrosion.
Replace service side panel to air heater and secure with the fixing screws.
40 RE-COMMISSIONING Recommission air heater as described in commissioning section of this manual.
4E SERVICE REPORT Upon completion of the service, report the facts to the customer or customer's representative and state in writing details of any faults found that require action and if the air heater(s) is being maintained sufficiently. If it is evident that a component might fail before the next service, this fact should also be reported in writing, thus making the person aware of the risk of a breakdown to the air heater.
4F BURNER REMOVAL
BURNER REMOVAL MODELS UH 100 - UH 140 - UH 180
BURNER REMOVAL MODELS UH 240 - UH 320
29
SECTION FIVE - FAULTS AND REMEDIES FAULT 5(i)
PILOTWILLNOT LIGHT
POSSIBLE CAUSE
REMEDY
1. Gas isolating cock turned off to unit 2. Incorrect lighting procedure
1. 2.
3.
Air in pilot gas line
4. 5.
Air in main gasline Dirt in pilot orifice
6. Bent or kinked pilot tubing, 7.
preventing gas flow Leakage in pilot line
8. Extremely high or low gas pressure
9. 5(i)
5(i)
5(i)
PI LOT GAS CAN BE LIT BUT GOES OUT WHEN PUSHBUTTON RELEASED
PILOT ESTABLISHED WHEN KNOB RELEASED BUT PILOT GOES OUT WH EN KNOB TURNED TO 'ON' PI LOT ESTABLISHED PUSH· BUTTON RELEASED, BUT BURNERS WILL NOT FIRE, i.e. NO MAIN BURNER GAS
10.
Blockage, valve or gas lines Insufficient pilot gas
1. 2.
Pushbutton released too soon. Loose thermocouple connection.
3. 4. 5.
Defective thermocouple Insufficient pi lot gas Faulty gas control valve
Follow lighting instructions in this manual Ensure connection clean and dry, then tighten correctly . 3. Replace thermocouple 4. Adjust pi lot gas rate 5. Replace gas valve
1.
Blockage in gas valve
1.
2. 3.
Insufficient pi lot gas. Insufficient main gas or too high main gas pressure.
2. 3.
1.
Power not switched on, or external controls (thermostat, timeswitch etc'! not calling for heat. Circuit to gas valve solenoid not made.
1.
2.
6.
Faulty transformer. Faulty thermostat . Faulty gas control valve solenoid operator High gas pressure
7.
Faulty gas control valve
1.
I ncorrect position of heater, too close to source of draught . Extraction fans in space being heated creating negative pressure which causes the products of combustion to be drawn back over burner. Incorrect flueing of heater. Leaking duct connection.
3. 4. 5.
5(i)
PILOT IS BLOWN OUT OR SMOTHERED BY FUMES
2.
3. 4. 50i)
50i)
MAIN BURNERS WILL FIRE BUT PILOT FLAME IS IMMEDIATELY EXTINGUISHED
MAIN BURNERS WILL NOT SHUT DOWN IN RESPONSE TO EXTERNAL CONTROLS
NO HEAT (HEATER OPERATING)
(FAN OPERATING)
1. 2.
Check clear blockage or replace as required. Adjust pilot gas rate . Check and adjust gas pressures as indicated in this manual. Switch on power, check fuses, turn up thermostat, ensure clock in on period.
Check 24 volt wiring earth continuity and connections, test gas valve, transformer, thermostat, 2 amp fuse and limit control switch(s). Replace parts as required. 3. Replace transformer. 4. Replace thermostat. 5. Replace gas control valve solenoid operator. 6. Check line pressure as indicated in this manual 7. Replace gas control valve 2.
1.
Reposition heater, eliminate draught.
2.
Provide adequate low level combustion air grilles and high level ventilation grilles to the area being heated.
3. Check flue installation as per BS5440 4. Make good jOint. 1.
Clean and ensure correct tightness.
2.
Dirty or loose thermocouple connection. Insufficient pilot gas.
2.
3.
Wrong size pilot jet fitted
3.
Pilot gas adjustment closed too far, reset as per the manual. Replace with correct size pilot jet
1.
Short circuit in external controls or wiring. Faulty gas valve solenoid operator. Dirt under gas valve seating, preventing valve closure.
1.
1.
2. 3.
4. Gas valve damaged due to overheating.
5(iil
Check, turn ON Follow instructions as indicated in this manual. Fully depress button on valve until all air 3. is purged from system (approx 1 minute) 4. Purge as per CP331 5. Remove pilot jet. Clean with solvent (DO NOT REAM) . (Refer to service section). Refit or replace . Replace tubing. Ensure compression olive 6. fitting not overtightened 7 . Check joints for gas tightness 8. Check gas line pressure and adjust as indicated in this manual 9. Clear blockages, replace as required 10. Pilot gas adjustment closed too far, reset.
Check wiring and controls, replace as necessary. Replace gas valve solenoid operator. 2. 3. Clean out valve with compressed air, find source of dirt, or fit strainer on gas line inlet. 4. Turn off gas to heat.er at nearest isolating cock. Then refer to section 3H of commissioning instructions.
1.
Incorrect manifold pressure or injectors fitted.
1.
2.
Cycling on limited control
2.
3.
Incorrect thermostat location or setting. No gas supply.
3.
4.
30
4.
Check line pressure as indicated in this manual, change injectors to the correct size for gas being used. Check air throughout . Ensure fans operate correctly. Check fan motors, capacitors and wiring . See thermostat instructions and wiring diagram supplied with this manual. Open gas cock and relight pilot.
SECTION FIVE - FAULTS AND REMEDIES FAULT 5(iii)
POSSIBLE CAUSE COLD AIR IS DELIVERED ON START UP, DURING OPERATION OR CONTINUOUSL Y WHEN BURNER IS OFF
1.
2. 3.
4. 5. 5(iij)
5(iii)
5(iii)
FAN MOTOR WILL NOT RUN
FAN MOTOR CUTS IN AND OUT WHILE BURNER IS OPERATING
FAN WILL NOT RUN (AND HUMS UNTIL FLICKED OR RUNS SLOWLY).
REMEDY
Summer/Winter switch (where fitted) set in summer position. Faulty fan control switch. Fan control anticipator incorrectly wired. Incorrect gas pressure. Ambient air temperature low i.e. cold start up.
Set to automatic/winter setting
2. 3.
Replace fan control switch. Rewire as per this manual or diagram inside wiring box cover. Adjust gas pressures as per this manual. Increase warm up period on time switch or ensure heater switched on earlier.
4. 5.
2. Fan control switch inoperative. 3 . Faulty capacitor 4. Faulty motor
2. 3. 4.
Check wiring and connections . Replace fan control switch. Replace capacitor Replace motor
1.
1.
Check wiring connection or replace.
2. 3.
Replace fan control switch. Maintain higher ambient air temperature in space bei ng heated.
4.
Check valve and pipework for blockage, ensure that gas pipework is correctly sized. Adjust gas pressure as per this manual.
1.
Replace fan motor capacitor
1.
Circuit open
1.
1.
Fan control anticipator improperly wired or defective. Faulty fan control switch. 2. 3. Low air temperature rise due to low ambient temperature causing fan switch to open and close. 4. Insufficient gas supply.
1.
Faulty capacitor.
31
SECTION SIX - SPARES LIST 6A PACK-A-WAY GAS FIRED UNIT HEATERS CONTROL LAYOUT UH 100 -140 -180
35
36 31
32--
~---~- 32
_ _ _
./
~
4
33
5 9
2 27---~ti L.L
37
29 - - - " 30 ---~
28 7
25 - - -_ _ 11
23 - - - - -
8
22 - - - -
25 20 12 13 21
24 14
1. Control Panel (Wiring Box) 2. Control Panel Cover Plate (NB . Wiring Diagram on reverse side) 3 . Data Plate 4. Main Terminal Block 240v 5. Burner Terminal Block 24v 6. Fan Control Switch CIW Anticipator 7. Limit Control Switch 8. Transformer 9 . Fuse Holder (2 amp fuse fitted) 10. Earth Point 11 . Service Union 12. Inlet Pressure Test Point 13. Gas Supply Line 14. Combined Gas Control Valve with 8uilt In Flame Failure Device and Pressure Regulator 15. Control Knob 16 . Pressure Regulator (Gas Control Valve) adjustment screw on top. 17. Solenoid Operator 24v 18. Thermocouple Line
19 . 20. 21. 22 . 23 .
15
Pilot Burner Gas Supply Line Burner Manifold Burner Pressure Test Point Pilot Burner Pilot Burner Lighting Hole with Mica Cover . . 24 . Burner Tray 25. Fixing Screws (Burner Tray) 26. Fan Motor 27. Fan Motor Capacitor 28. Fan Motor Electrical Cable 29 . Fan 30. Fan Guard 31 . Flue Socket 32. Suspension Eyebolts 33 . Downdraught Diverter Vent 34. Base Panel Conduit Knockout 35 . Top Panel Electrical Conduit Entry Holes. 36 . Top Panel Gas Entry Hole. 37. Horizontal Adjustable Louvres.
32
SECTION SIX - SPARES LIST
68
35
PAK-A-WAY GAS FIRED UNIT HEATERS
_ _ __ _ _ _CONTROL _ _LAYOUT _~UH 240 - 320
36
32
31 ___ ~
32 - - - -- - ...
~
6
33
3
4
2
~_--9
10 ~-1--37
27 -
-
-...,-&lo.l
39 -----::-IIr.r+W
7
29
11
28
8
25
25
23
12
22
13
20
18
21 24
19
17
1. Control Panel (Wiring Box) 2. Control Panel Cover Plate (NB. Wiring Diagram on reverse side) 3. Data Plate 4. Main Terminal Block 240v 5. Burner Terminal Block 24v 6. Fan Control Switch C/W Anticipator 7. Limit Control Switch 8. Transformer 9 . Fuse Holder (2 amp Fuse Fitted) 10. Earth Point 11 . Service Union 12. I nlet Pressure Test Point 13. Gas Supply Li ne 14. Combined Gas Control Valve with built in Flame Fail ure Device and Pressure Regulator .
15. 16 . 17. 18 . 19. 20 . 21. 22. 23 . 24 . 25. 26 . 27. 28 . 29. 30.
Start Control Knob Stop Control Knob Solenoid Operator 24v Thermocouple Line Pilot Burner Gas Supply Line Burner Manifold Burner Pressure Test Point Pilot Burner Pilot Burner Lighting Hole with MICA cover . Burner Tray Fixing Screws (Burner Tray) Fan Motor Fan Motor, Capacitor Fan Motor (Electrical Cables)
Fan
Fan Guard
33
31. 32. 33 . 34 . 35 .
FI ue Socket Suspension Eyebolts Down Draught Diverter Vent Base Panel Conduit Knockout Top Panel Electrical Conduit Entry Holes 36. Top Panel Gas Entry Hole 37 . Horizontal Adjustable Louvres 38. Pressure Regulator (Gas Control Valve) Adjustment screw on top 39 . Wiring to Second Limit Control Switch fitted in other side of Heater.
,
/
• \f RT1
,
.... - , 1·\
I RT2 I
"
,
I
't--( I
I
lh I~ I 11
I
"'-0-+-- ....
1M2 \
L
0
!
-~
I
+---t-~
..... _"
---21.0 V
N
I I
,'.- '_...J
V FC FCA LCl LC2 Ml M2 T 2A 'RTl *RT2
I
-
,
,.
I
I
L_ --./ M2i----l
:' ...RT1: -,-
\
I
ELECTRO-MAGNETIC GAS CONTROL VALVE FAN CONTROL SWITCH (240V) FAN CONTROL SWITCH ANTICIPATOR (24V) OVERTEMP LIMIT CONTROL SWITCH OVERTEMP LIMIT CONTROL SWITCH (UH240 ti UH320 MODELS ONLY) FAN MOTOR FAN MOTOR (UH240 II< UH320 MODELS ONLY) TRANSFORMER (240V-24V) FUSE (24V-2AMP) ROOM THERMOSTAT 240V (OPTIONAL) ROOM THERMOSTAT 24V (OPTIONAL)
SPECIAL NOTE
, , _ ,II
1.
To connect thermostat remove link between terminals 5 and 6 (240V)or 11 and 12 (24V) as appropriate.
....... ,
2.
For timeswitch, fused electrical isolator, and thermostat connections refer to drawing numbers 0998EUH (24V) and 0999EUH (240V).
(RT2)
3.
If thermostat used is 24V and has an adjustable anticipator set to the correct reading by adding appropriate current for the controls listed below.
,
~-1
r---~~~~4,.]~-...J-...J---r~----------~
Fan control switch anticipator
0.1 AMPS
V8600 Gas control valve (UH 1OO-UH 140-UH 180)
0.2 AMPS
V8800 Gas control valve (UH240-UH320)
0.2 AMPS
i.e. 24V Thermostat anticipator setting
0.3 AMPS
ON NO ACCOUNT SHOULD THE 24 VOLT WIRING OF ONE AIR HEATER BE CONNECTED TO THAT OF ANOTHER HEATER, EXCEPT VIA A RELAY HAVING SEPARATE SWITCH CONTACTS OR A PAK-A-WAY CONTROL PANEL. IF IN ANY DOUBT CONSULT THE PACKAGE HEATER COMPANY, SALES OFFICE, ADDRESS AND TELEPHONE NUMBER AS BELOW.
(PAK-A-WAY) THE PACKAGE HEATER Co. FORT ROAD LlTTLEHAMPTON SUSSEX BN17 7EF. Tel: (0903) 725945
MODELS UH100-UH140-UH180-UH240 & UH320 SINGLE PHASE 240V
34
DATE 2/1/86
DRAWN W .G.J.
DRG No. 23301EUH PT No3062473
THERMOSTAT AND/OR MANUAL SWITCH CIRC UI 1.
fUSED ELE[TRICAL ISOCATfJR [IRCUIT
l. - - - - . - - - - N---+----e---
220/240 V AC Single Phase Supply
*" Manual
E~----t----t__1~--
*
ON/Off
Thermostat
On IOff
240V
Switch
flee trical Isolator fused A f 5 Amp Rating.
[!]'0 00 5
00~0
HEA TER
HEATER TERMINAL STRIP
6 []
TERMItJAL STRIP
TIMES WITCH , THERMOSTA T AND NIGHT SETBACK THERMOSTAT (fROS T STA T) CIRCUIT
TIHESWJTCH AND THERMOSTAT CIRCUIT
Thermosta/~
Thermostat 240 V
240V
00000 HEATER TERMINAL STRIP Sutj!J.ULJ~ENJ.1.L~ TI ON
567
HEA TER TERMINAL STRIP SUMMER/WINTER SWITCH
. QN _ Lr S W_I_T_CH .iI_R_C_Ul_T
*
[J,RCUIT
Summer/ Wir. fer Swiici;
On/Off Switch (240 V)
( 24 () 1/) 3
CD 000
000 45 00 HEATER TERMINA L 5 TRIP
4 5 6 []
HE ATER TERMINAL S TRI P
NOTES.
On no account should the 24 Volt wiring of one heater be connected to that
1.
Items marked' ARE NOT supplied by Pak-A-Way.
of another heater, except via a relay having separate switch contacts or a
2.
ON/OFF switching must always be made via the 24V Circuit. On no account must the main electrical supply to the air heater be switched OFF except when servicing or in emergency when the gas supply to the heater must be turned off as well. (Refer to installation manual for further information).
3.
Pak-A-Way control panel. If in any doubt consult the Package Heater Company, Sales Office, Address and telephone number as below.
All wiring must be in accordance with the I.E.E. Regulations and any local codes of practice that may apply.
(PAK-A-WAY)
MODELS UH100-UH140-UH180-UH240 & UH320 USING 240 VOLT THERMOSTATS (NOTE: TO BE READ IN CONJUNCTION WITH DRAWING No. 23301 EUH)
THE PACKAGE HEATER Co.
FORT ROAD LlTTLEHAMPTON SUSSEX BN17 7EF. Tel_' (0903) 725945
35
DATE 2/1/86
DRAWN W.G.J.
DRG No.
0999EUH
FUSED ELECTRICAL ISO[ATOR CIRCUIT
L -......- - - N---+--t--- E...---+--+--t_-
THERMOSTAT AND/OR MANUAL SWITCH CIRC ul T.
220/240 V AC Singl e Phase Supply
*
E lectrical Isolator Fused At 5 Amp Rating.
ON/OFF Manual On/Off Switch .
Thermostat 24V
*
0~~0 HEATER TERMINAL STRIP
HEATER TERMINAL STRIP TIMESWITCH AND THERMOSTAT CIRCUIT
TIMESWITCH. THERHOSTA T AND NIGHT SETBACK THERMOSTAT (FROST STA T) CIRCUIT
Thermos tat
Thermos tat
@000050 7
~0~ HEATER
TERMINAL
SUMMER VENTILATION
L?JL?J~1J
HEA TER TERHINAL STRIPS
STRIPS
ONLY SW!TC H CfRCUIT
S U!1!1ER/ WIN TE R SWITCH
CIRCUIT
* On/Off Switch (240 V)
000 45 00
(0000 456 0
HEATER TERMINAL STRIP
HE ATER TERHINAL S TRI P
NOTES.
WARNING - TIME SWITCHES.
1.
Items marked' ARE NOT supplied by Fak-A-Way.
Timeswitches must be fitted with separate motor connections when switch
2.
ON/OFF switching must always be made via the 24V Circuit. On no account must the main electrical supply to the air heater be switched OFF except when servicing or in emergency when the gas supply to the heater must be turned off as well. (Refer to installation manual for further information).
contacts are being used to control the 24V circuit.
All wiring must be in accordance with the I.E.E. Regulations and any local codes of practice that may apply.
If in any doubt consult the Package Heater Company, Sales Office, Address
3.
(PAK-A-WAV)
On no account should the 24 Volt wiring of one heater be connected to that
of another heater, except via a relay having separate switch contacts or a
Pak-A-Way control panel.
and telephone number as below.
MODELS UH1 00-UH140-UH180-UH240 & UH320 USING 24 VOLT THERMOSTATS (NOTE: TO BE READ IN CONJUNCTION WITH DRAWING No. 23301 EUH)
THE PACKAGE HEATER Co.
FORT ROAD LlTTLEHAMPTON SUSSEX BN177EF. Tel: (0903) 725945
36
DATE 2/1/86
DRAWN W.G.J,
DRG No.
0998EUH
~
/'ii"
240X _ _
\ RT2 I
E.r--- -
"- -'1/ I
I
I
I
I
I
I
,.
I I L_J
I I
~1.
'------~ I
/-~LJ J ( H2 -t----+
HEATER WIRING MODIFICATION The lead(s) from the overtemp limit control switch(es) wired internally as standard to terminal 11, must be disconnected and rewired into terminal 8 as shown on this wiring diagram. The terminals on the venter and heater are then connected directly between each corresponding number.
..-.J.
\_ ./~-4----+-------J
AI
1- -
--
I'LU'
I ~ L
,_/
t -
On no account should the 24 Volt wiring of one heater be connected to that of another heater, except via a relay having separate switch contacts or a Pak-A-Way control panel.
I
-
,
I
I
I
~4 V
:J
J
---' - --.= ~
I L
If in any doubt consult the Package Heater Company, Sales Office, Address and telephone number as below.
-'----iro-.-"..t----'
240 V
N
-1..
V FC FCA LC1 LC2 M1 M2 T 2A VM VR VRS AS 'RT1 *RT2
For timeswitch, electrical isolator, thermostat and summerIwinter switch connections refer to drawing numbers 0998EUH (24V) and 0999EUH (240V).
ELECTRO-MAGNETIC GAS CONTROL VALVE FAN CONTROL SWITCH (240V) FAN CONTROL SWITCH ANTICIPATOR (24V) OVERTEMP LIMIT CONTROL SWITCH OVERTEMP LIMIT CONTROL SWITCH (UH240 & UH320 MODELS ONLY)
FAN MOTOR
FAN MOTOR (UH240 & UH320 MODELS ONLY)
TRANSFORMER (240V-24V)
FUSE (24V-2AMP)
VENTER FAN MOTOR
VENTER RELAY (24V)
VENTER RELAY SWITCH (240V)
AIR SAIL SWITCH (24V)
ROOM THERMOSTAT 240V (OPTIONAL) ROOM THERMOSTAT 24V (OPTIONAL)
SPECIAL NOTE 1.
To connect thermostat remove link between terminals 5 and 6 (240V) or 11 and 12 (24V) as appropriate.
2.
If thermostat used is 24V and has an adjustable anticipator, set to the correct reading by adding appropriate current for the controls listed below. Fan control switch anticipator
0.1 AMPS
V8600 Gas Valve (UH100-UH140-UH180)
0.2 AMPS 0.2 AMPS
V8800 Gas Valve (UH240-UH320)
0.125 AMPS
Flue venter relay
i.e. 24V Thermostat anticipator setting 0.425 AMPS minimum with venter fitted. 3.
( PAK-A-WAY ) THE PACKAGE HEATER CO.
FORT ROAD LlTTLEHAMPTON SUSSEX
BN177EF. Tel: (0903) 725945
All wiring must be in accordance with the I.E.E. regulations and any local codes of practice that may apply.
MODELS UH100-UH140-UH180-UH240 & UH320 USING A FLUE VENTER SINGLE PHASE 240V DATE DRAWN DRG No.
37
2/1/86
W.G.J.
23302EUH
( PAK-A-WAY)
JANUARY 1986
COVERS PAK-A-WAY MODELS UHIOO-UH140-UH180-UH240-UH320
USERS INSTRUCTIONS
HANG THIS CARD NEAR YOUR HEATER WARN ING: This appliance must be earthed . IMPORTANT In the interest of safety and user satisfaction, these instructions should be rea d and fu lly understood. To operate safely and efficiently t his appliance must be serviced regularly by a competent person. Seek advice of your installer or local Gas Region Service Centre who will arrange for a service or cont ract service. Difficu lties in this regard should be addressed in writing to the manufactu rer's office. Failu re to accept this advice could affect applicable warrantees. GENERAL Pak-A -Way U.H. Model Heaters are designed and manufactured to 'provide many years of rel iable service. PA CKAGE HEATER have built into your air heater safety, quality, reliability and good performance. Every appliance is factory inspected and tested and comprehen sive instructions have been provided to the installer in an endeavour to ensure t hat your heater is correctly fitted and commissioned so that it will do the job for which it is designed. HOW THE A IR HEATER WORKS A gas burner is controlled on an d off by a t hermostat and/or a time switch control, which can be regulated by t he user. A permanent pilot burner is employed to light the gas burner and is used to maintain a safety sensor for automatic shut down in the event of flame failure, thus preventing unburnt gas escaping to cause a hazard. The burner heats a sealed steel Heat Exchanger from which products of combustion are exhausted via flue system t o t he outdoor atmosphere. When the temperatu re in t he air heater casing reaches a prescribed degree, thermally activated switches switch on the air circulation fan and in the event of overheating shut down the burner thus ensu ring the safe operat ion. The air circulation fan w ill not start at the same t ime as the burner and will continue to run when t he burner has shut down. This ensures that cold air w ill not be blown from the heater and that t he heater is cooled adequately at the end of the heating cycle. NOTE Left and right definitions referred to in these instructions are assuming that discharged air will blow onto the face of the viewer.
TO START THE AIR HEATER 1. Ensure that t he main gas supply to the air heater is ON. 2. Switch OFF t he electricity supply to th e air heater. 3. Set room thermostat to OFF or its LOWEST sett ing. If fitted, ensure t ime switch is set to an ON period . 4. Press in fully the start button on the gas control va lve (models UH100, UH 140 and UH180) or t he whit e sta rt button (models UH240 and UH320) and at the same time apply a lighted match or taper to the pilot burner. 5. On ce the pilot is alight, continue to keep the button f ully depressed for at least 20 seconds before releasing. If the pilot f lame goes out turn t he start button (models UH100, UH140, UH 180) clockwise about a quarter tu rn, wait 3 minutes t hen repeat from step (4). For models UH240, UH320 push in the red button, wait 3 minutes, t hen repeat from step 4. 6. Wit h th e pilot flame established replace the pilot port w indow and burner compartment access panel. 7. Switch ON t he electricity supply to the air heater. 8. Adjust room thermostat to desired temperature or switch on control switch as applicable and main burner wi ll light.
TO TU RN OFF THE AIR HEAT ER For short periods Adjust the room thermostat to lowest setting or OFF, or if fitted switch OFF t he manual control switch . The air heater will remain ready for use immediately th ese controls are re-adjusted . To turn OFF completely for a prolonged period
LIGHTING & OPERATING INSTRUCTIONS BEFORE STARTING THE AIR HEATER Ensure that all warm air louvres and ducting grilles, if fitted, are open. Locate the pilot burner an d gas cont rol valve which are situated behind the bottom hinged lower access panel on the left hand side of the air heater. The pilot burner is directly behind the lighting port window. (figs 1 or 2) WARNING: IF THE PILOT LIGHT IS EXTINGUISHED EITH ER INTENTIONALLY OR UNINTENTIONALLY NO A TTEM PT SHOULD BE MADE TO RELIGHT THE GAS UNTIL AT LEAST 3 MINUTES HAVE ELAPSED .
a. Switch OFF manual cont rol sw itch and t urn room thermostat to OFF or LOWEST setting. b. Turn the start button on the gas control valve for models UH100, UH140, UH 180 clockwise about a quarter turn . For models UH240 & UH320 push in the red stop button on the gas control. This shuts down the gas supply to t he main and pilot burners. c. Wait 5 minutes and then switch OFF t he main electricity supply to the air heater, and turn OFF the gas supply using the externally located gas tap.
AIR CIRCULATION Some Pak-A -W ay Unit A ir Heaters are connected to an air fan over ride switch. This enables forced air to be used for circulation purposes when the heater is not used for heating purposes, i.e. Summer months. a. Switch ON mains electricity to the air heater. b. Switch ON the manual over-ride switch . c. Where fan over-ride switch is not f itted, turn off gas supply, turn up setting on room thermostat. Fan w ill start after approx. one minute. During the low ambient temperature periods (i .e. cold morning sta rt up) the air circulation fan may run and stop at irregu lar intervals. This is due to the cold air being drawn t hrough the air heater cooling the t hermostatic fan switch to below its normal constant runnin g temperature. This is norma l and will be automatically corrected as t he ambient temperature rises. Fig.l. Lighting Instructions
UH 100 - UH140 - UH 180
MAINTENANCE AND SERVICING Maintenance and service must only be carried out by com petent persons. Periods between service are dependant upon t he local environment where t he air heater is installed. Regular inspection is recommended initially to ascertain routine intervals and where loca l environmental circumstances change, i. e. different processes being ca rried out in a factory, the servi ce interval should be reconsidered. Ask your installer, service undertaking or t he manufacturer about inspection and service intervals.
TH E AIR HEATER SHOULD BE SERVICED AT LEAST ONCE EVERY HEATING SEASON . PAK-A-WAY UH AIR HEATERS ARE APPROVED BY BRITISH GAS FOR USE ON NATURAL GAS. Fig. 2. Li gh t ing Instructions UH240 - UH3 20
Heater Model UH f
THE PACKAGE HEATER CO .
Fort Road Littlehampton Sussex BN17 7 EF . Tel: (0903) 725945
~ Serial Number ~------~ REMARKS : Use of this type of heater in corrosive or inflammable atmosphere is not recommended. Warranty is void if heater is operated in the presence of ch lorinated vapours. MODELS & DATA: Subject to modification without prior notice .
SERVICE RECORD
INSTALLED BY
DATE COM MISSIONED
