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Pactrol P14 Retrofit Kit

Pactrol P14 Retrofit Kit


Ref 706106 TB106 Pactrol P14 Retrofit Kit TB.106.0316

Note: Bulletin to be used in conjunction with the ER Operating and Installation manual.


The original Pactrol P14 metal clad sequence controller is no longer available for the older range of ER22 and ER38 radiant tube heaters (c1979 - 1983).

ER22/38 burners built during this period also included various gas valves/regulators, various mains input and fan output connectors. The wiring also incorporated a 230V 2 pole relay.

This bulletin describes the parts required and, due to the variance in components, a ‘generic’ method of fitting a replacement P16 controller (fig.2) and supplement parts required to achieve this.

A retrofit kit part number 2015-P14KIT will be available to include a P16 ignition controller, replacement main wiring harness, mini harness, HT & probe leads, wiring connectors and fixings.


Procedure

Isolate any electrical supply to the heater and controller before proceeding. It is recommended to remove the burner from the radiant tube and carry out the retrofit at floor level.

Remove the side cover of the burner control housing by removing the screws.

Disconnect the Octal plug HT lead and sensor probe lead from the P14 controller.

Disconnect the Live, Neutral and Earth harness cables from the mains input socket*

Disconnect the Live, Neutral and Earth harness cables from the fan output socket*

If the fan output socket is of an Octal style, the fan may have a motor with a separate capacitor situated inside the control housing. This must be left in situ.

(* these cables may connected either be via push on spade connectors or even soldiered. If they are soldiered, snip the wires to leave a tail to be connected to the replacement harness later.)

Disconnect the cables connected to the pressure switch.

Disconnect any harness cables connected to the gas valve(s). The gas valve may be either a combined Honeywell V4400 type or single Technigas solenoid valve and separate governor.

Remove the 2 screws fixing the Octal relay base to the burner box.

The remaining section of harness/relay should now be withdrawn from the burner.

Remove the eyelet ring from the earth stud by removing the nut and serated washer.

Remove the combustion chamber lid by removing the 6 screws. Detach the rectification/sensor lead and electrode/spark lead from the probe assembly.

If both leads are in two halves, you will need to remove the panel receptacle from the bulkhead.

Position the replacement Pactrol P16 inside the burner. Mark two diagonal holes, drill the holes using a 5mm drill bit and fix the controller in place using two M4 x 10 screws and nuts.

Connect 12 way JST male connector of the new harness to the female connector of the P16 ensuring positive lock.

Distribute the harness roughly to the correct position. The harness has been pre-cable-tied so the correct group of cables are in the relative position to the items they connect to. It may be necessary to snip off some of the cable ties to make it easier. There should be :-

1. A group of four connectors for the males on and burner on neons. One with a single RED wire, one with a double BROWN wires and two joined connectors with BLUE wires. Attach the red and one of the BLUE wired connectors to the red neon, the brown and the other BLUE wired connector to the amber neon.

2. A group of three connectors for the pressure switch. One with a single YELLOW wire, one with a single GREY wire and one single BLACK wire. Attach the YELLOW wired connector to the ’normally closed’ (n.c.) of the pressure switch, the GREY wired connector to the ’normally open’ (n.o.) of the pressure switch and the BLACK wired connector to the ’common’ (c.) of the pressure switch.

3. A group of three connectors* for the mains input socket. One with a single BROWN wire, one with a single BLUE wire and one single YELLOW/GREEN cable. Attach the BROWN wired connector to the Live (L) connection of the mains input socket, the BLUE wired connector to the Neutral (N) connection of the mains input socket and the YELLOW/GREEN wired connector to the Earth (E) connection of the mains input socket. These cables may be soldered. If they are, snip the spade push-on connectors off wires to leave a tail and connect to the tails left when removing the original harness with a 3 way terminal block.

4. Connect the eyelet on the harness to the earth stud using the serated washer & nut.

5. A group of three cables for the fan output*. One with a single BLACK wire, one with a single BLUE wire and one single YELLOW/GREEN cable. Attach the BLACK wired connector to the Live (L) connection of the fan output socket, the BLUE wired connector to the Neutral (N) connection of the fan output socket and the YELLOW/GREEN wired connector to the Earth (E) connection of the fan output socket. (* these cables may be soldered. If they are, snip the spade push-on connectors off wires to leave a tail and connect to the tails left when removing the original harness with a 3 way terminal block.)

6. A group of three cables terminated with a 3 way female plug JST. This is to be joined to a separate short wiring lead terminated with a 3 way male socket JST. This male socket JST has a single RED wire, a single BLUE wire and a single YELLOW/GREEN cable for the gas valve**. (**Dependent on the model, these cables may connected either directly to the solenoid valve via push on spade connectors (supplied) or to a 3 way terminal connector situated on the rear wall of the burner housing.

RED wire = Live, BLUE wire = Neutral YELLOW/GREEN wire = Earth.

7. Place the brown rectification cable through the hole in the bulkhead and connect to the probe assembly.

8. Place the grey spark cable through the hole in the bulkhead and connect to the probe assembly.

Replace the combustion chamber lid by firstly removing any excess fibre/rubber material from around the lid and flange. Position the new gasket and fix the lid in position using he existing 6 screws.

Replace the burner onto the radiant tube ensuring the burner is in the correct orientation. Fix by tightening the two grub screws.Replace the fan plug into the socket.

Replace the mains lead.

Test the correct operation of the burner before replacing the controls cover.

Click on Article Attachment below to follow the step by step instructions.

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Article Attachments
706106 TB106 P14 Retrofit Kit ARAD EN 0316 A3F TB.106.0316.pdf

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Last Modified on 12/07/2016.
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