Pguh Service Manual Oct2002
Pguh Service Manual Oct2002
Pguh Service Manual Oct2002
CONTENTS
Section Title Page
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Introduction Technical Data General Requirements Installation Air Distribution System Commissioning & Testing Servicing Connections to External Controls Fault Finding Short List of Parts
Tables
Title
Page
Dimensions Specifications Injector Sizes & Burner Pressures Natural Gas - Group H - G20 Injector Sizes & Burner Pressures Propane - G31 Injector Sizes - Butane - G30 Electrical Loadings 1ph Damper Settings PGUH 'C' Units
3 3 4 4 4 5 5
Figure
Title
Page
Controls Location PGUH 12 Controls Location PGUH 15 - 150 Pilot Flame Adjustment SIT Nova 820 Honeywell V4605C High/Lo and Modulating Heads Cross Lighting Assembly Detail PGUH 15 - 150
9 9 9 10 10 11 12
1. INTRODUCTION
The Powrmatic PGUH range of gas fired natural draught, open flued, fanned circulation air heaters cover a heat output range of 11.7kW to 150.0kW. They are certified for us on Natural Gas, Group H - G20, Propane - G31 and, with the exception of the PGUH 12, Butane - G30. Appliance Categories are:PGUH 12 - Cat II2H3P PGUH 15 - 150 - Cat II2H3+. The heaters are designed to be suspended from suitable roof points or alternatively to be mounted on purpose designed brackets and are intended primarily for heating commercial or industrial premises. PGUH-F heaters have an axial fan assembly fitted at the rear to circulate the air being heated through the clam-shell heat exchanger. A centrifugal fan variation is presented in the PGUHC range for use with ducted systems and the PGUH-D range, in having no fan fitted, is for ducted systems where the air moving fan is by others. Heaters are fitted with atmospheric bar burners, a low energy permanent pilot ignited by a piezo spark generator, a multifunctional control for gas supply control and safety functions, a fan timer and limit thermostat. Options include automatic ignition by a full sequence control with low level reset, High/Low or modulating burner controls, inlet duct connection/fan silencer, outlet duct connection, 45 head, 90 outlet bend, nozzle outlet and vertical/horizontal outlet louvre assembly. Each air heater must be connected to an individual open flue system only. The draught diverter is integral with the heater.
B C E D F
2 Technical Data
B E A
C H
D F
Front View
A J
PGUH 45 - 75 'C' Version Shown
G#2
Side View
G #1
2
C E
B D F
Front View
G#1
Table 1 Dimensions
A
PGUH 12 PGUH 15 PGUH 22 PGUH 30 PGUH 45 PGUH 52 PGUH 60 PGUH 75 PGUH 90 PGUH 105 PGUH 120 PGUH 150
1083 960 700
B
480
C
450
D #1 D #2
320 320
E
390
F
125
G #1 G #2
535 680 818 1207 1020 692 1207
H
360
J
347
462
150
720
N/A
1025
795
887
925
663
870
1615
1477
1516 250
1460
1598
1915
1777
1815
938
1760
1808
D #1 - Front, D #2 - Back
Table 2 - Specifications
HIGH FIRE MODEL INPUT (Nett) OUTPUT kw PGUH 12 PGUH 15 PGUH 22 PGUH 30 F C F C F C F C F PGUH 45 PGUH 52 PGUH 60 PGUH 75 PGUH 90 PGUH 105 PGUH 120 PGUH 150 C F C F C F C F C F C F C F C 170.45 150.0 85.23 75.0 2.985 4.0510 119.32 136.36 105.0 120.0 59.66 68.18 52.5 60.0 2.1138 2.4872 2.8694 3.3754 85.23 102.27 75.0 90.0 42.61 51.14 37.5 45.0 1.4925 1.741 2.0255 2.3626 59.66 68.18 52.5 60.0 29.83 34.09 26.25 30.0 1.0569 1.2436 1.4347 1.6877 51.14 45.0 25.57 22.5 0.8705 1.1813 25.57 34.09 22.5 30.0 12.78 17.05 11.25 15.0 0.6327 0.8438 0.8060 1.0740 13.20 17.05 12.0 15.0 7.90 8.52 LOW FIRE INPUT (Nett) AIR VOLUME High MAXIMUM DUCT RESISTANCE Standard pa 0.3375 0.5370 N/A 100 7.5 0.4219 N/A 194 N/A 260 N/A 232 N/A 212 N/A 145 N/A 74 N/A 120 N/A 212 N/A 145 N/A 74 N/A 120 N/A 125 N/A 170 N/A 245 N/A 245 N/A 155 N/A 165 N/A 200 N/A 40 N/A 155 N/A 165 N/A 200 N/A 40 0.030 0.335 0.040 0.355 0.100 0.550 0.100 0.550 0.100 0.560 0.120 0.560 0.370 0.990 0.370 0.750 2 x 0.100 2 x 0.560 2 x 0.120 2 x 0.990 2 x 0.370 2 x 0.990 2 x 0.370 2 x 0.750 High FAN MOTOR Standard kw 0.08 0.55 0.10 0.55 0.18 0.75 0.25 1.10 0.37 1.10 0.41 1.50 0.50 1.50 0.50 1.50 2 x 0.37 2 x 1.10 2 x 0.41 2 x 1.50 2 x 0.50 2 x 1.50 2 x 0.50 2 x 1.50 50 56 98 110 98 110 98 110 134 155 134 155 134 155 153 185 268 310 268 310 268 310 310 374 High WEIGHT kg
Table 3.1 Injector Sizes & Burner Pressures Natural Gas - Group H - G20 Net CV (Hi) = 34.02MJ/m Inlet pressure 20mbar
Inlet Pressure 20mb MODEL PGUH 12 PGUH 15 PGUH 22 PGUH 30 PGUH 45 PGUH 52 PGUH 60 PGUH 75 PGUH 90 PGUH 105 PGUH 120 PGUH 150 No. 4 5 6 8 6 7 8 10 12 14 16 20 INJECTORS Size mm 1.59 1.51 1.7 1.7 2.46 2.46 2.46 2.46 2.46 2.46 2.46 2.46 Marked 159 151 170 170 246 246 246 246 246 246 246 246 High Fire Burner Gas Rate Pressure mbar 13.7 18.2 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 15.5 m/h 1.40 1.8 2.7 3.6 5.41 6.31 7.21 9.01 10.81 12.63 14.43 18.02 Low Fire Burner Gas Rate Pressure mbar 4.9 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 m/h 0.84 0.90 1.35 1.80 2.71 3.12 3.61 4.51 5.41 6.31 7.21 9.01
Pilot Injector Front Orifice dia 0.38 mm Rear Orifice dia 0.355 mm Pilot Rate 0.1 kW
Table 3.2 Injector Sizes & Burner Pressures - Propane G31 - Net CV (Hi) = 116.09MJ/m Inlet Pressure 37mbar
Inlet Pressure 20mb MODEL PGUH 12 PGUH 15 PGUH 22 PGUH 30 PGUH 45 PGUH 52 PGUH 60 PGUH 75 PGUH 90 PGUH 105 PGUH 120 PGUH 150 No. 4 5 6 8 6 7 8 10 12 14 16 20 INJECTORS Size mm 1.14 0.93 1.04 1.04 1.45 1.45 1.45 1.51 1.45 1.45 1.45 1.51 Marked 114 120 150 150 280 280 280 300 280 280 280 300 High Fire Burner Gas Rate Pressure mbar 22.0 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A m/h 0.54 0.70 1.05 1.39 2.09 2.44 2.79 3.48 4.19 4.88 5.58 6.97 Low Fire Burner Gas Rate Pressure mbar 6.8 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A m/h 0.32 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
Pilot Injector Front Orifice dia 0.20 mm Rear Orifice dia 0.23 mm Pilot Rate 0.1 kW
Table 3.3 Injector Sizes & Burner Pressures Butane G30 Net CV (Hi) = 88.00MJ/m Inlet pressure 29mbar
Inlet Pressure 20mb MODEL PGUH 12 PGUH 15 PGUH 22 PGUH 30 PGUH 45 PGUH 52 PGUH 60 PGUH 75 PGUH 90 PGUH 105 PGUH 120 PGUH 150 No. N/A 5 6 8 6 7 8 10 12 14 16 20 High Fire Burner Gas Rate Pressure mbar N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A m/h N/A 0.53 0.79 1.06 1.58 1.85 2.11 2.64 3.17 3.70 4.23 5.28
INJECTORS Size mm N/A 0.93 1.04 1.04 1.45 1.45 1.45 1.51 1.45 1.45 1.45 1.51 Marked N/A 120 150 150 280 280 280 300 280 280 280 300
Pilot Injector Front Orifice dia 0.20 mm Rear Orifice dia 0.23 mm Pilot Rate 0.1 kW
Standard Airflow MODEL PGUH 12F PGUH 15F PGUH 22F PGUH 30F PGUH 45F PGUH 52F PGUH 60F PGUH 75F PGUH 90F 1500 900
MOTOR R.P.M. PLATE AMPS (A) START RUN FUSE AMPS AMPS RATING (A) (A) (A)
High AirFlow
MOTOR
R.P.M. PLATE AMPS (A) START RUN AMPS AMPS (A) (A) FUSE RATING (A)
0.35
0.46 0.28 1.5 0.78 1.8 0.94 1.6 1.23 1.60 1.10 1.80 1.33 6.10 1.95 5.50 2.50 3.20 2.20
1500
2 3 3
4.00
5 7 10
PGUH 105F 2 x 1.00 3.60 2.70 2 x 1000 PGUH 120F 12.20 3.90 2 x 3.00 PGUH 150F 11.00 5.00 PGUH 12C PGUH 15C PGUH 22C PGUH 30C PGUH 45C PGUH 52C PGUH 60C PGUH 75C PGUH 90C PGUH 105C PGUH 120C PGUH 150C 2 x 1000 2 x 7.40 1000 7.40 2 x 4.10 1000 900 2.60 5.80 2.80 1.80 9.0 5.40 9.0 5.50 9.0 5.50 9.80 3.20 11.0 3.80 13.0 5.50 37.0 6.60 20.0 6.50 22.0 7.00 26.0 11.0 74.0 13.0
5 7 3 7
2 x 2.57 17.8 5.40 10.4 7.74 2 x 4.00 17.0 7.80 2.60 5.4 7.40 5.40 3.60 4.70 32.0 4.80 6.00 32.0 6.40 32.0 8.60 36.0 7.50 36.0 9.20 7.40 64.0 12.80 64.0 17.20 72.0 15.00 72.0 18.40
5 7 7 10 13 20
4.10
5 1500 7 10 13 15
9.50
9.50
Pa Pa Pa Pa Pa Pa Pa Pa Pa Pa Pa Pa
PGUH 105C 2.1138 m/s PGUH 120C 2.4872 m/s PGUH 150C 2.985 m/s
3. General Requirements
3.1 Related Documents
The installation of the air heater(s) must be in accordance with the rules in force and the relevant requirements of the Gas Safety Regulations, Building Regulations and the I.E.E. Regulations for Electrical Installations. It should 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. British Gas Plc Publications IM/11 : 1989 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters IM/16 : 1988 Guidance notes for the installation of gas pipework, boosters and compressors in Customers premises (excluding domestic installation of 25mm and below). British Standards Code of Practice BS 5588 -11 : 1997 Fire precautions in the design, construction and use of buildings. Code of practice for shops, offices, industrial, storage and other similar buildings BS 6230:1991 Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial Space Heating. Those appliances having an input rating not exceeding 60kW viz. PGUH 12 to PGUH 52 inclusive must be installed in accordance with the relevant recommendations of the following documents. BS 5440 Flues and Air Supply for gas appliances of rated input not exceeding 60kW (1st and 2nd family gases). Part 1 - Flues, Part 2 - Air Supply
connection of the heater. The complete installation must be tested for soundness as described in the above Code. The complete installation must be tested for soundness as described in BS 6230.
3.3.4. Boosted Supplies Where it is necessary to employ a gas pressure booster the controls must include a low pressure cut off switch at the booster inlet. The local gas undertaking must be consulted before a gas pressure booster is fitted. The maximum inlet pressure is 60mb.
3.2 Location
The location chosen for the air heater must permit the provision of a satisfactory flue system and an adequate air supply. The location must also provide adequate space for servicing and air circulation around the air heater. The heater(s) must not be installed in conditions for which it is not specifically designed e.g. where the atmosphere is corrosive or salty and where high wind speeds may affect burner operation, and they are not suitable for outdoor use. Where the location of the air heater is such that it might suffer external mechanical damage e.g. from overhead cranes, fork lift trucks, it must be suitably protected. PGUH units are designed to operate in a maximum ambient temperature of 25 C.
60 kW total rated input. (b) High Level (outlet) (1) for heaters of total rated heat input less than 60 kW: 4.5 cm per kilowatt of rated heat input; (2) for heaters of total rated heat input 60kW or more: 270 cm plus 2.25 cm per kilowatt in excess of 60kW total rated input. All air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour. Air vents should be so designed that high velocity air streams do not occur within the plant room.
It must have a contact separation of at least 3mm in all poles. The method of connection should be provided adjacent to the air heater(s) in a readily accessible position. See the accompanying wiring diagram for the heater electrical connections PGUH units can also be supplied for 400V 3N, 50Hz
All models Any combustible material adjacent to the air heater and the flue system must be so placed or shielded as to ensure that its temperature does not exceed 65 C IMPORTANT: No air heater shall be installed where there is a foreseeable risk of flammable particles, gases and vapours or corrosion inducing gases or vapours being drawn into either the heated air stream or the air for combustion. In such cases installation may only proceed if the air to be heated and the air for combustion are ducted to the heater from an uncontaminated source preferably outside the building. In certain situations where only airborne particles are present it may suffice to fit filters on the air inlet ducts of the heater. Advice in these instances may be obtained from Powrmatic Ltd.
Before installing the heater any existing trusses, walls, brackets etc., must be inspected to ensure they are suitable. All supports should be protected against the effects of corrosion. If noise levels are of particular importance the heater should be insulated from the structure of the building by installing it on suitable anti-vibration mountings. In all such cases and, in addition, when the heater is suspended all gas, duct, electrical and flue connections to the heater must be made with flexible connections. In the case of the flue connection single wall stainless steel flue is deemed to flex sufficiently to meet the requirements.
being connected to Neutral. Under no circumstances must the fan motor electrical supply be taken direct from the internal wiring of the PGUH.
6.2
Gas Installation
The whole of the gas installation, including the meter, should be inspected and tested for soundness and purged.
6.3
The system should be checked to ensure that the installation work has been carried out in accordance with the design requirements. Particular attention should be given to the correct arrangement of delivery ducts and registers, return air ducts and grills and general adequacy of return air paths. For PGUH C standard airflow units the fan damper must be set to match the resistance of the ductwork (SeeTable 5 (Page5). PGUH C high airflow units are matched to the published duct resistance and the ductwork must be balanced accordingly (See Table 2 (Page3).
6.4
The following preliminary checks should be made before lighting the heater(s)
a) b) c) d) e) f)
Ensure that the ELECTRICAL supply to the heater is switched OFF. Check that all warm air delivery outlets are open. Check that the thermostat is set at MAX. Check that the clock control is set to an ON period. Check that any other controls are calling for heat. Check that the overheat reset button has not operated.
connection using a leak detection fluid. NOTES: 1. When attempting to light the pilots at any time ensure that the mains electricity supply is switched off. 2. On initial lighting of the heater(s), it may take some time to purge the internal pipework of air.
6.5
WARNING: The multifunctional gas control(s) is operated by 230 volts. IMPORTANT: The internal pipework of the appliance has been tested for soundness before leaving the factory. After establishing the pilot(s) and with the main burners alight test round the gas inlet
7
Fig. 1a Controls Location PGUH 12
8 6 5
P IL
OT
5 6
2 1
Fig.2 Pilot Flame Adjustment
9 - 12mm
2
PIL
OT
E 6 4
Fig. 3b - Honeywell V4605C
1. 2. 3. 4. 5. 6. 7. Governor adjustment cover screw. Electrical connections for main valve operator. Earth connection. Safety shut off valve. Safety shut off valve electrical connections. Inlet pressure test point. Inlet pressure test point.
A 7 1 3 8 2
7
1a ,1b - 3) several times keeping the multifunctional control knob depressed. The pilot flame may be viewed through the viewing port in the side of the burner tray. (Figs. 1a &1b - 4) 4. Ensure that the pilot flame fully envelopes 9-12mm of the thermocouple tip (See Fig. 2) and, if necessary adjust the pilot regulating screw (Fig.3a - 3) . 5. Once the pilot has been established continue pressing the control knob for approximately 30 seconds and then slowly release. The pilot should remain alight. WARNING: Should the pilot be extinguished at any time, either intentionally or unintentionally, slightly depress the control knob and rotate clockwise to OFF. Wait 3 minutes before attempting to relight the gas, then repeat steps 3-5 above. 6. Slightly depress the control knob and turn to On. 7. Switch on the electricity supply at the isolator, and the main burners will light. 8. SHUT OFF To interrupt all gas flow through the multifunctional control slightly depress the control knob and rotate clockwise to OFF. CAUTION The restart interlock device prevents the heater from re-igniting because the flame supervision device has interrupted the gas flow. After waiting 3 minutes the heater may be relit by following the previous instructions from 6.5. 6.5.1.2 Models PGUH 90 - 150. (SIT 820 NOVA MFC) 1. Follow steps 6.5.1.1.1 to 6.5.1.1.6 and establish the left hand pilot. 2. Follow steps 6.5.1.1.1 to 6.5.1.1.6 and establish the right hand pilot.
3. Switch on the electricity supply at the isolator and the main burners will light. 4. SHUT OFF To interrupt all gas flow through the multifunctional controls slightly depress the control knobs and rotate clockwise to OFF. CAUTION The restart interlock device prevents the heater from re-igniting because the flame supervision device has interrupted the gas flow. After waiting 3 minutes the heater may be relit by following the previous instructions from 6.5.
6.5.2. Auto Ignition Units 6.5.2.1 All Models 1. Switch on the electrical supply at the isolator and the ignition sequence will commence. After a delay of approximately 30 seconds the ignition spark will be generated and the main gas valves energized. The burners will then light. Note: On PGUH 90 - 150 units the left hand (viewed from the front) burner set will light first. Only when this burner set is lit will the right hand burner set begin its ignition sequence. 2. If the burners fail to light the control box will go to lockout and the lockout light on the low level remote reset will be illuminated. To restart the ignition sequence depress the reset button on the low level reset. 3. SHUT OFF Set the clock control to OFF or set the room thermostat to MIN.
6.6 Adjustments
6.6.1 Burner Gas Pressure This is set for the required heat input before despatch. In the case of Hi/Lo and Modulating units both high and low pressures are set. Pressures should be checked in the following manner. For models PGUH 90-150 inclusive follow the instructions below for both sets of burners whilst both sets are alight.
10
6.6.1.1 Standard & Auto Ignition Units 1. Set external controls to ensure that the main burner is off. Open the access door on PGUH 15 - 150. Connect a pressure gauge to the burner pressure testpoint on the multifunctional control. 2. Set external controls so as to turn on the main burner. Compare the measured burner gas pressure to that stated in Section 2. 3. If necessary adjust the burner gas pressure by removing the cover screw (Fig 3a -2, Fig 3b - 1) and turning the regulator screw anticlockwise to decrease the pressure, or clockwise to increase the burner pressure. 4. In addition it is advisable to check the gas rate using the gas meter dial pointer. Ensure that no other appliances supplied through the meter are in operation. 5. Turn off the main burner as in 6.6.1.1.1 disconnect the pressure gauge and retighten the sealing screw. Turn on the main burner as in 6.6.1.1.2. and test for gas soundness around pressure test joint using a leak detection fluid. Close access door on PGUH 15-150. 6.6.1.2 High/Lo and Modulating Units 1. Set external controls to ensure that the main burner is off. Open the access door and connect a pressure gauge to the outlet pressure testpoint on the multifunctional control. 2. Set external controls so as to turn on the main burner and maintain high fire. Compare the measured burner gas pressure to that stated in Section 2. In addition it is advisable to check the gas rate using the gas meter dial pointer. Ensure that no other appliances supplied through the meter are in operation. 3. Repeat 2 above with external controls set to maintain low fire. 4. If it is necessary to adjust the high pressure setting then proceed from step i). If it is only necessary to adjust the low fire pressure setting proceed from step vii). Refer to Fig.4 i) Set external controls to turn main burner OFF. ii) Pull back the clip retaining the actuator coil to its mounting stem and remove the coil. iii) Set external controls to turn main burner ON. iv) Screw adjustment screw A fully clockwise. v) Release the M13 locknut E that secures the actuator stem into the mfc governor and turn the actuator stem to set the HIGH FIRE pressure (clockwise to increase pressure). vi) Tighten the locknut without further turning the actuator stem. vii) Unscrew adjustment screw A to set the LOW FIRE pressure (anti clockwise to decrease pressure). viii) Set external controls to turn burner OFF and replace valve body C onto the valve stem ensuring that it clips into position and then re check the pressures. 5. Turn off the main burner as in 6.6.1.1. disconnect the pressure gauge and retighten the sealing screw. Turn on the main burner as in 6.6.1.2. above and test for gas soundness around pressure test joint using a leak detection fluid e.g. soap solution. Close access door.
6.6.2 Down Draught Diverter 1. Check that there is no spillage of products of combustion from the air heater down draught diverter by carrying out a spillage test by testing for CO (A smoke test may give misleading results due to general air movement at the draught diverter). 6.6.3 Air Heater Controls 6.6.3.1 Standard Units 1. Check that the flame failure device will shut off the gas to the main burner within 60 seconds by turning off the gas supply at the gas service valve. A distinct click will be heard when the thermocouple current is no longer sufficient to hold in the magnetic unit. 2. Check that the room thermostat and all automatic controls are operating satisfactorily. 6.6.4 Fan Timer Fan operation is controlled by an electronic timer. The timer is set prior to despatch so that the air fan starts approximately 15 seconds after the burners light. This delay may be increased to 30 seconds by turning clockwise the adjustment on the front of the timer with a small screwdriver, or decreased down to zero by adjusting anticlockwise. The timer provides a non adjustable fan off time of 150 seconds after the controls turn off the burners.
7. Servicing
WARNING: Always switch off and disconnect electricity supply and close the gas service valve(s) before carrying out any servicing work or replacement of failed components. NOTE: 1. The following instructions refer specifically to Models PGUH 12-75. For Models 90-150 inc repeat the instructions so that both sets of components are fully serviced. 2. If a suspended air heater is to be serviced do not lean ladders against the heater. Ensure that an access tower or equivalent is used.
7.1 General
Full maintenance should be undertaken not less than once per year by a qualified person. After any servicing work has been completed or any component replaced the air heater(s) must be fully commissioned and tested for soundness as described in Section 6.
A B C D1 E F
D2
11
igniter in the rear lower panel. 6. Remove the burner tray complete, from the front of the air heater, by pulling forwards. For suspended air heaters it is recommended that the burner assembly is taken down to floor level before proceeding. 7. Release the screws securing the cross lighting strip assembly and remove the assembly. 8. Remove the anti flame roll strip at the injector end of the burner tray. 9. Remove each burner from its injector and using a stiff brush (not wire), brush the flame strips to dislodge accumulated deposits. Inspect the burners both internally and externally to ensure that they are clean. Examine the injectors and if damaged or deteriorated, replace with new ones of the correct size and marking (see Section 2 - Tables 3.1, 3.2 or 3.2). If deemed necessary, clean the injectors. Do not broach out with wire. NOTE: If a full service is being undertaken then complete sections 7.3 and 7.4 before continuing. 10. Reassemble the injectors, burners anti flame roll strip and cross lighting assembly etc in reverse order to that above.
wire. NOTE: If a full service is being undertaken then complete sections 7.3 and 7.4 before continuing. 8. Reassemble the injectors, burners and cross lighting assembly in reverse order to that above. CAUTION: Ensure that the cross lighting strip is assembled as shown in Fig 5 - Item 2 locates under the rolled edge around the burner flame strip and Item 1 abuts onto the top of the burner.
7.2.2 PGUH 15 - 75 1. Ensure that the gas service valve is turned OFF. 2. Open the access door. 3. Remove the plug(s) (Fig 3a - 8, 3b2&5) from the multifunctional valve. 4. Remove the inner burner securing plate by removing the securing screws. 5. Pull the burner tray out. For suspended air heaters it is recommended that the burner assembly is taken down to floor level before proceeding. 6. Release the nuts securing the cross lighting strip assembly and remove the two strips (see Fig 5, - 1 & 2 Page 12) 7. Remove each burner by lifting up at the cross lighting strip end and then disengaging from its injector. Using a stiff brush (not wire), brush the flame strips to dislodge accumulated deposits. Inspect the burners both internally and externally to ensure that they are clean. Examine the injectors and if damaged or deteriorated, replace with new ones of the correct size and marking (see Section 2 - Tables 3.1, 3.2 and 3.3). If deemed necessary, clean the injectors. Do not broach out with
7.4 Flueways
Whilst the main burner assembly is removed from the appliance the flueways should be cleaned by brushing upwards from the burner tray compartment. For suspended units the heater base may be hinged down after removing the screws at the bottom of the lower front panel. If it is necessary to gain access to the top of the heat exchanger then for PGUH 15-150 1. Disconnect first length of flue fitted to the flue outlet (for PGUH 90 - 150 also remove the Y branch) 2. Remove the screws, accessed through the side panels, securing the top/upperfront panel inplace and remove panel. 3. Remove the draught diverter and then the inner baffle plate. 4. Renew the sealing gaskets and reassemble in the reverse order to that above. 5. Re-commission the appliance as described in Section 6.
12
1. Inspect the fan blades to see that they are not damaged and that there is no excessive build up of deposits that could give rise to an imbalance. Should it be necessary to remove the assembly for cleaning proceed as follows. 2. Slacken the cable gland nut on the heater casing through which the fan electrical cable passes. (Fig 1a or 1b - 5). 3. Remove the right hand side panel (PGUH 12 Fig 1a - 8) or open the access door (PGUH 15-150 Fig 1b - 9) and disconnect the fan leads from the electrical terminals and withdraw cable. 4. Remove the fan and motor assembly complete by removing the four hexagon headed bolts that secure the fan to the rear panel. 5. Reassemble in reverse order.
door (PGUH 15 - 150). 2. Remove the two screws securing the phial braket and withdraw bracket. 3. Unclip the thermostat phial. 4. Disconnect the electrical leads from the thermostat by pulling off the connectors. 5. Release the thermostat from the electrical panel. 6. Fit the new thermostat in reverse to the above steps. NB. Ensure that the thermostats are set correctly before fitment - see following table. LIMIT THERMOSTAT SET POINT PGUH 60, 120 - 80C PGUH 12, 45, 52, 75, 90, 105, 150 - 90C PGUH 15 - 100C PGUH 30 - 110C
7.5.2 PGUH C Models 1. Inspect the fan blades to see that they are not damaged and that there is no build up of excessive deposits that could give rise to an imbalance. Should it be necessary to remove the assembly for cleaning proceed as follows. 2. Slacken the cable gland nut on the heater casing through which the fan electrical cable passes (Fig 1a or 1b - 5). 3. Remove the right hand side panel (PGUH 12 Fig.1a - 8) or open theaccess door (PGUH 15-150 Fig 1b - 9) and disconnect the fan leads from the electrical terminals and withdraw cable. 4. Where fan capacitor is mounted on rear of appliance remove the two screws that secure the cover box. 5. Remove the complete fan assembly by removing the nuts securing the fan to the rear panel.
7.6.6 Fan Timer 1. Release the four timer leads from the terminal block and r e m o v e t h e t w o s c r e w s s e c u r i n g t h e t i m e r. 2. Fit the new timer and reassemble in reverse order. 7.6.7 Fan and Motor Assembly Note: On 3ph heaters ensure that the fan direction of rotation corresponds with the direction of rotation arrow on the fan guard or case. If necessary reverse the direction of rotation by interchanging any two of the motor live leads at the terminal strip in the electrical panel. 7.6.7.1 PGUH F Models 1. Remove the complete axial fan assembly as described in Section 7.5.1. 2. Refit axial fan assembly to the heater in reverse order. On 3ph units the direction of fan rotation must be checked. If it is incorrect reverse any two of the live wires to the fan motor.
7.6.7.2 PGUH C Models 1. Remove the complete centrifugal fan assembly as described in Section 7.5.2. 2. Fit the new centrifugal assembly in reverse order. On 3ph units the direction of fan rotation must be checked. If it is incorrect reverse any two of the live wires to the fan motor.
7.6.2 Burner Bars 1. Remove the burner assembly and dismantle it as previously described in Section 7.2. NOTE: It is not necessary to disturb the pilot assembly. 2. Exchange those burner bars as required and reassemble components in reverse order. 3. Re-commission the appliance as described in Section 6. 7.6.3 Pilot Assembly 1. Remove the burner assembly as previously described in Section 7.2 and remove the pilot assembly as described in Section 7.3. 2. Fit the new pilot assembly and reassemble in reverse order. 3. Re-commission the appliance as described in Section 6. 7.6.4 Piezo Unit 1. Remove the right and left hand panels (PGUH 12) or open the access door (PGUH 50 - 150). 2. On the PGUH 12 remove the lower rear panel after having released the burner assembly See 7.2.1.. 3. Disconnect the spark ignition lead from the rear of the piezo unit. 4. Unscrew the backnut of the piezo unit and withdraw the unit. 5. Fit the new unit, reconnect the spark ignition lead and reassemble in reverse order. 7.6.5 Limit Thermostat 1. Remove the right hand panel (PGUH 12) or open the access
13
7 5
7 5
VENT
SENSOR
VENT CLOCK O/P HEAT IN HEAT OUT
POWRTROL
SENSOR
L N
N L E
7 5
7 5
RF
ROOM STAT
ROOM STAT
RF
TIME SWITCH
14
EUROTROL
9.
Fault Finding
Cause Electrical Action 1. No spark - check ignition lead connections - check spark electrode gap - See Section 7.3. - faulty piezo igniter - change - faulty control box - change (auto ignition units). 1. Check gas supply to pilot assembly. 2. No pilot flame - See Section 6. 3. Start button on multifunctional control not depressed for long enough. 1. Faulty thermocouple - check connections- change 2. High limit thermostat tripped out - check for reason, rectify and reset. 3. Faulty multifunctional control - change 1. Pilot flame too small - check - See Section 6. 1. 2. 3. 4. 5. Check electrical supply is ON. Check controls are ON or calling for heat. Faulty multifunctional - change. No ignition spark or rectification signal (auto ignition units) Control box at lockout - reset, or faulty - change (auto ignition units)
Gas
Electrical
Main burner lights, but goes out before main fan comes on.
1. Unit goes out on high limit a. Check Fan command module (timer) operation. b. Check limit thermostat setting - See Section 7.6.5. Relight pilot as in Section 6 c. Faulty limit thermostat - change. Relight pilot as in Section 6. d. Faulty fan assembly - change. 2. (Ducted Units Only) -fan motor out on thermal overload. - Allow motor to cool then check running amps See table 4. - check duct resistance See Table 5. Electrical Electrical 1. Summer/Winter switch and/or external controls set to Summer. 2. Fan command module (timer) faulty - change. 1. Fan motor or capacitor failed - replace. 2. Fan command module (timer) faulty - change. 3. Fan contactor failed - replace (3ph units)
15
ITEM
MFC - SIT Nova 820 0.820.063 MFC - Honeywell V4605C 1029B Pilot Assembly - Honeywell Q359A1058 Pilot Injector - Honeywell 45004108-001B (0.38mm / 0.355mm) Pilot Injector - Honeywell 45004114-005 (0.20mm / 0.23mm) Pilot Compression Fitting - Honeywell 4500062-002 Ignition Electrode - Morgan & Matroc 61028 Ignition / Rectification Electrodes - Johnson 27B2P6T0000CIW Thermocouple - Johnson 2800B0 (600mm) Thermocouple - Orkli T50 (900mm) Piezo Unit - Morgan & Matroc 66156 Burner Bar - Bray AB 17510 Burner Bar - Bray AB 17509 Thermostat - Limit - IMIT LS/1 L2 Fan Command Module (timer) Contactor - Danfoss CI4-5+1 037H311433 Full sequence control - Pactrol P16HI/VB4(CE) Hi/Lo Governor Head - Anglo Nordic MD20003 Modulating Governor Head - Anglo Nordic MD1003/MD Amplifier board - Johnsons PIB-24
APPLICATION
ALL - Std ALL - /AI ALL - Std ALL - Std - NG ALL - Std - Propane ALL - Std ALL - Std ALL - /AI ALL - Std 150 ALL - Std 45 - 150 12 - 30 ALL ALL ALL - /C, /3 ALL - /AI ALL - /HL ALL - /MOD ALL - /MOD
PART NUMBER
142400439 142400431 142403002 1424402801 142402823 142400404 142423121 142400625 142403832 142403833 142436021 142400212 142400234 142403609 142403605 143016131 142400421/H 142466410 142466421 142400304
HEATING DIVISION
Winterhay Lane Ilminster, Somerset TA19 9PQ Tel: 01460 53535 Fax: 01460 52341
Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.