Roberts Gorden Combat Cabinet Heaters Pop Eca Pgp 015 To 0100 Users Manual CCH Heater IOS
POP-ECAPGP-ECA 015 to 0100 to the manual 818cabb4-5ca5-4b18-9063-f20e4441bd5d
2015-02-06
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FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. DO NOT try to light any appliance. 3. DO NOT use electrical switches. 4. DO NOT use any telephone in your building. 5. Leave the building. 6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions. 7. If you cannot reach your gas supplier, call the Fire Department. WARNING Combat ® Cabinet Heaters Installation, Commissioning, Operation & Service Manual OIL-FIRED: Model POP-ECA 015 to 0100 Fire Hazard Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance. GAS-FIRED: Model PGP-ECA 015 to 0100 Some objects will catch fire or explode when placed close to heater. Failure to follow these instructions can result in death, injury or property damage. WARNING Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the installation, operation and service manual thoroughly before installing or servicing this equipment. Installation must be done by a registered installer/ contractor qualified in the installation and service of gas/oil-fired heating equipment or your fuel supplier. Quality in Any Language™ © Copyright 2008 Roberts-Gordon LLC Installer Please take the time to read and understand these instructions prior to any installation. Installer must give a copy of this manual to the owner. Owner Keep this manual in a safe place in order to provide your serviceman with necessary information. Roberts-Gordon Europe Limited Unit A, Kings Hill Business Park Darlaston Road, Wednesbury West Midlands,WS10 7SH UK Telephone: +44 (0)121 506 7700 Fax: +44 (0)121 506 7701 Service Telephone: +44 (0)121 506 7709 Service Fax: +44 (0)121 506 7702 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com P/N X523 Rev G 10/08 TABLE OF CONTENTS SECTION 1: Heater Safety...................................................... 2 SECTION 2: Installer Responsibility ..................................... 2 2.1 Clearances to Combustibles ........................................ 2 2.2 Corrosive Chemicals.................................................... 2 2.3 National Standards and Applicable Codes .................. 2 SECTION 3: Critical Considerations ..................................... 3 3.1 Basic Information ......................................................... 3 3.2 Location and Suspension ............................................ 3 3.3 Minimum Required Installation Clearances ................. 3 3.4 Clearances to Combustibles ........................................ 3 3.5 Ventilation .................................................................... 3 3.6 Fuel Supply .................................................................. 3 3.7 Electrical Supply .......................................................... 3 3.8 Flue.............................................................................. 3 SECTION 4: Specifications .................................................... 5 4.1 PGP & POP Internal Heaters....................................... 5 4.2 PGP & POP External Heaters ..................................... 6 4.3 Air Outlet and Flue Arrangements ............................... 7 4.4 General Technical Data Table (all models) Appliance Category II 2H/L 3B/P ....................................... 8 4.5 Technical Data - Ecoflam ON/OFF Burners (all models - burner reference "C") .............................. 8 4.6 Technical Data - Ecoflam Modulating Burners (all models - burner reference "H") .............................. 9 4.7 Technical Data - Ecoflam Oil-Fired Burners (burner reference "G") ............................................... 10 SECTION 5: Heater Installation............................................ 11 5.1 General ...................................................................... 11 5.2 Handling .................................................................... 11 SECTION 6: Flue Installation ............................................... 13 6.1 Flue Installation.......................................................... 13 SECTION 7: Air Supply......................................................... 15 7.1 Air Supply ................................................................... 15 7.2 Isolated Equipment Rooms ........................................ 15 7.3 Building Ventilation ..................................................... 15 7.4 Distribution Ducting .................................................... 15 7.5 Return Air Ducting ...................................................... 15 SECTION 8: Fuel Piping........................................................ 16 8.1 Connections............................................................... 16 8.2 Fuel Oil Supply .......................................................... 17 SECTION 9: Wiring and Electrical Information................... 19 9.1 Electrical Supply ........................................................ 19 9.2 Remote Controls ........................................................ 19 9.3 CCH Wiring Diagram Gas Models 15-30 (floor standing)........................................................... 20 9.4 CCH Wiring Diagram Oil Models 15-30 (floor standing)........................................................... 21 9.5 CCH Wiring Diagram Gas Models 15-30 (horizontal mounting)................................................. 22 9.6 CCH Wiring Diagram Oil Models 15-30 (horizontal mounting)................................................. 23 9.7 CCH Wiring Diagram Gas Models 40-50 (floor standing)........................................................... 24 9.8 CCH Wiring Diagram Oil Models 40-50 (floor standing)........................................................... 25 9.9 CCH Wiring Diagram Gas Models 40-50 (horizontal mounting)................................................. 26 9.10 CCH Wiring Diagram Oil Models 40-50 (horizontal mounting) ............................................... 27 9.11 CCH Wiring Diagram Gas Models 60-100 (floor standing) .........................................................28 9.12 CCH Wiring Diagram Oil Models 60-100 (floor standing) .........................................................29 9.13 CCH Wiring Diagram Gas Models 60-100 (horizontal mounting) ...............................................30 9.14 CCH Wiring Diagram Oil Models 60-100 (horizontal mounting) ...............................................31 9.15 Final Connections to Ecoflam HIGH/LOW or Modulating Burners (all models) ..............................32 SECTION 10: Commissioning ..............................................33 10.1 Pre-Commission Checks ..........................................33 10.2 Commissioning the Burner (gas heaters).................34 10.3 Control - Gas-Fired Heaters .....................................35 10.4 Gas Valves ...............................................................37 10.5 Combustion Testing (all models) ..............................37 10.6 Commissioning the Burner (Oil Heaters)..................38 10.7 Control - Oil-Fired Heaters .......................................38 10.8 Turning Off the Heater (all models) ..........................39 10.9 External Controls......................................................39 10.10 Instruction to the User ............................................39 SECTION 11: User Instructions............................................40 11.1 User Instructions .......................................................40 11.2 Common User Controls (all models) .........................40 11.3 Lighting Instructions (all models) ..............................41 11.4 Simple Fault Finding (all models)..............................41 SECTION 12: Servicing.........................................................43 12.1 Servicing Instructions...............................................43 12.2 Burner Maintenance.................................................43 12.3 Fan/Motor Assembly Maintenance (all models) .......43 12.4 Heat Exchanger Maintenance ..................................43 12.5 Thermal Insulation ...................................................43 SECTION 13: Conversion Between FUELS .........................44 13.1 General ....................................................................44 13.2 Burner Conversion ...................................................44 SECTION 14: Troubleshooting .............................................45 14.1 General ....................................................................45 14.2 Troubleshooting for Oil Burners (see manufacture’s instructions) ..............................46 14.3 Troubleshooting for Gas Burners (see manufacturer’s instructions) .............................47 14.4 Troubleshooting for Flame Supervision System .......48 14.5 Troubleshooting for Solenoid Valves Circuit .............49 14.6 Troubleshooting for Main Fan Circuit (1 Ø)...............49 14.7 Troubleshooting for Main Fan (3 Ø)..........................50 SECTION 15: Removal and Replacement Parts..................51 15.1 Burner Components ..............................................51 15.2 Direct On-Line Main Fan Starter and Thermal Overload Unit (3 Ø) ...................................51 15.3 Control Circuit Fuse (10 or 5 A, 1-1/4" long sand filled)............................51 15.4 Combination Fan/Limit Thermostat ..........................51 15.5 Main Fan Motor (3 Ø Belt Drive) ..............................51 15.6 Main Fan Units .........................................................51 SECTION 16: Parts List.........................................................53 16.1 Spare Parts List........................................................53 © 2008 Roberts-Gordon LLC All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Roberts-Gordon LLC. Printed in U.K. TABLE OF FIGURES Figure 1: Installation Clearances and Clearances to Combustibles ............................................................. 4 Figure 2: Typical Installation of a Gas Fired Cabinet Heater ... 11 Figure 3: Typical Installation of a Oil-Fired Cabinet Heater ..... 12 Figure 4: Flue Termination ...................................................... 13 Figure 5: Offset Flues with 135° bends ................................... 13 Figure 6: Guy Wire .................................................................. 14 Figure 7: Socket Direction....................................................... 14 Figure 8: Flue and Roof Detail ................................................ 14 Figure 9: Flue and Heater Spigot Joint Detail ......................... 14 Figure 10: Gas Connection ..................................................... 16 Figure 11: B. M. Oil Lifter......................................................... 17 Figure 12: Pressurised System Installation - Duplex System .. 18 Figure 13: Combination Thermostat (all models) .................... 34 Figure 14: Gas-Fired Heater Control Box Sequence............... 35 Figure 15: Motor Starter (models 040 -100 and Thermal Overload (models 060 - 100) ................................. 36 Figure 16: Gas Train Circuit for Dungs Gas Valves (all models) ............................................................ 36 Figure 17: Dungs Gas Valve ................................................... 37 Figure 18: Oil-Fired Heaters Control Box Sequence ............... 38 Figure 19: Heater Operating Sequence .................................. 40 Figure 20: Fan/Limit Thermostat ............................................. 40 Figure 21: Belt Tension ........................................................... 43 Figure 22: Combination Fan/Limit Thermostat........................ 52 Product Approval ROBERTS GORDON ® appliances have been tested and CE certified as complying with the essential requirements of the Gas Appliance Directive, the Low Voltage Directive, the Electromagnetic Compatibility Directive and the Machinery Directive for use with natural gas and LPG when installed, commissioned and maintained in accordance with these instructions. These instructions refer to gas appliances designed to operate in the European Union. Appliances designed for other countries (Non-European Union) are available on request. Oil-fired versions are constructed to the same basic design criteria to burn fuel oil as specified below, but no similar testing is available for these products at the time of writing. Oil-fired appliances should be operated in accordance with local rules and laws. Oil heaters are supplied as standard for use with Gas Oil, also known as 35-second Oil, Red Diesel, Class D or Class A2. They are also available to order for Kerosine, also known as 28-second Oil or Class C2. These appliances must be installed in accordance with the local and national codes in force and used only in a sufficiently ventilated space, as specified in these instructions. Before installation, check that the local gas distribution systems, nature of gas and pressure, and adjustment of the appliance are compatible. 1 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 1: HEATER SAFETY clearances to combustibles. Affix the tag on a wall Your Safety Is Important to Us! near the heater. This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay 2.2 Corrosive Chemicals special attention when reading and following the warnings in these sections. Installation, Service and Annual Inspection of heater must be done by a registered installer/contractor Do not use heater in an area containing corrosive qualified in the installation and service of gas/oilchemicals. fired heating equipment. CAUTION Read this manual carefully before installation, operation, or service of this equipment. Burner manufacturers manual is also provided to give detailed instructions on the operation of the burner. The settings for use of the burner with the heater are shown in these instructions. This heater is designed for heating non-residential indoor spaces. Do not install in residential spaces. These instructions, the layout drawing, local codes and ordinances, and applicable standards that apply to gas piping, electrical wiring, venting, etc., must be thoroughly understood before proceeding with the installation. SECTION 2: INSTALLER RESPONSIBILITY • To install the heater, as well as the fuel and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon recommends the installer contact a local building inspector, Fire Officer or insurance company for guidance. • To use the information given in this manual together with the local and national codes to perform the installation. • To install the heater in accordance with the Clearances to Combustibles of this heater. • To furnish all needed materials not furnished as standard equipment. • To plan location of supports, flues and air intakes. • To provide access to burners for servicing. • To provide the owner with a copy of this installation, commissioning, operation and service manual. • To never use heater as support for ladder or other access equipment and never hang or suspend anything from heater. • To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant local and national codes. 2.1 Clearances to Combustibles In all situations, clearances to combustibles must be maintained. Caution must be used when running the heater near combustible materials such as wood, paper, rubber, etc. A wall tag is on the back cover of this manual as a permanent reminder of the safety instructions and the importance of the required 2 Corrosive chemicals will damage the burner and heat exchanger parts. Failure to follow these instructions can result in property damage. Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere on the premises. * Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the lifespan of the heater components will be greatly reduced. Warranty will be invalid if the heater is exposed to halogenated hydrocarbons. 2.3 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of applicable standards and local and national codes. This refers also to the electric, gas and venting installation. NOTE: Additional standards for installations in Public Garages, Aircraft Hangars, etc. may be applicable. The main relevant regulations for installation within the UK are: • Gas safety (installation and use) regulations, 1984 and amendments - 1996. • BS6230 - Specification for the installation of gas fired forced convection air heaters for commercial and industrial space heating of rated input exceeding 60kW. (This standard also applies to oil-fired heaters, except for the fuel supply). • BS6230 - Parts 2 & 3, fire precautions in the design and construction of buildings. • BS6891 - Low pressure installation pipes. • BS5410 - Codes of practice for oil firing. Part 2 installation of 44 kW and above output capacity for space heaters, hot water and steam supply purposes. • Institute of Gas Engineers document IGE/UP/2. • Building regulations. • IEE regulations. • Health and safety at work acts. • Requirements of local authority, fire officer and insurance company. SECTION 3: CRITICAL CONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information Cabinet heaters are supplied with burners suitable for on/off operation as standard. As an option, oilfired burners are available with two-stage operation and gas-fired burners are available with full modulation. 3.2 Location and Suspension All models: • Are designed to be installed indoors within the heated space. Special versions are available for installation outdoors. • Are designed for floor standing vertical installation. • Must be installed in a manner which allows all the upper panels and either of the lower side panels to be removed to provide access to all serviceable components. • Must be placed on a firm, level, non-combustible surface that can support its weight. See Page 5, Section 4.1 for weight details. Horizontal models: • Special versions supplied with steel channels to support the heater are available and may be mounted horizontally. When installed horizontally, the heater will normally lie on its left side when viewed from the burner. The same clearances and comments on panels must be used, except for the side the heater lies on. 3.7 Electrical Supply A permanent 230 V, 50 Hz, 1 Ø is required on models 15 to 30 and 400 V, 50 Hz, 3 Ø and neutral required on models 40 to 100 (special version PGP and POP 040 and 050 models are available as belt drive). The heater also requires suitable energy controls in accordance with Section 9. ON/OFF control, temperature control, time control, and frost protection are available as a remote control, which needs to be site wired for proper operation of the heater. Alternatively, any remote energy controls may be used which must be wired in accordance with Section 9.3 through Section 9.10. 3.8 Flue Choose heater siting to allow for the proper location of the flue. Each heater must be fitted with an individual and correctly sized sealed flue system (See Page 13, Section 6). 3.3 Minimum Required Installation Clearances Clearances around the heater and flue must be as indicated on Page 4, Figure 1 and Page 13, Figure 4 through Figure 5 to ensure access for servicing, and correct operation. 3.4 Clearances to Combustibles Clearances must be as indicated on Page 4, Figure 1. If no clearances to combustibles are indicated, then installation clearances apply. 3.5 Ventilation It is important to ensure adequate air circulation around the heater to supply air for combustion, ventilation and distribution in accordance with local and national codes. 3.6 Fuel Supply It is important that the fuel supply pipe is sized correctly to provide the inlet pressure as stated on the heater data plate. The fuel supply pipe and electrical connections must not support any of the heater's weight. 3 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL WARNING Fire Hazard Some objects will catch fire or explode when placed close to heater. Keep all flammable objects, liquids and vapours the required distance away from the heater. Failure to follow these instructions can result in death, injury or property damage. Figure 1: Installation Clearances and Clearances to Combustibles .6 m .6 m 4m .6 m *.6 m *.6 m The flue pipe must have clearance from combustibles by 5 cm. If installed where individuals can come in contact with the pressure relief door or other hot components, adequate guarding must be provided. All distances are minimum clearance requirements for service access, air flow and safety. *A service clearance of 1m is required on one side to allow for fan replacement. 4 SECTION 4: SPECIFICATIONS SECTION 4: SPECIFICATIONS 4.1 PGP & POP Internal Heaters Front View (all models) Rear View (all models) Side View (Models 060 - 0100) Side View (Models 015 - 050) D D E C G A 70 38 G G F B 38 70 38 F B 38 108 38 38 H Dimension Data - PGP & POP Internal Heaters A Width B Depth, Cabinet Only C Height, Cabinet Only D Depth, Overall E Height, Including Heads F Left/Right Air Inlet Spigot - Depth G Left/Right Air Inlet Spigot - Height H Rear Air Inlet Spigot - Depth J Rear Air Inlet Spigot - Height Flue Diameter* Weight Model 015/020 030 040 050 060/070/080 0100 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 724 29 857 34 1740 69 1267 50 1988 78 781 31 457 18 648 26 361 14 178 7 724 29 857 34 1740 69 1267 50 2058 81 781 31 457 18 648 26 361 14 178 7 857 34 857 34 1930 76 1337 53 2235 88 781 31 560 22 781 31 446 18 178 7 1016 40 1016 40 1930 76 1496 59 2235 88 940 37 560 22 781 31 446 18 178 7 1016 40 1676 66 1930 76 2156 85 2235 88 1600 63 560 22 1016 40 1994 79 1930 76 2496 98 2235 88 1918 76 559 22 NA NA NA NA 229 9 229 9 kg 200 200 245 270 440 530 NOTES: Horizontal cabinet heaters are designed to lie on their left side as standard. For vertical models, add 54 mm (2 in) to the right side of the cabinet for the fan/limit thermostat. For horizontal models, add 54 mm (2 in) to the top of the cabinet for the fan/limit thermostat. *All heaters must be connected to a suitable flue constructed of single wall stainless steel. 5 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.2 PGP & POP External Heaters Front View Rear View Side View 275 F H D G P J 50 C C L M 70 38 A N B 108 38 38 E 38 K A Dimension Data - PGP & POP External Heaters A Width B Depth, Cabinet Only C Height, Cabinet Only D Depth Overall E External Heater Housing F Width Overall G Air Outlet Spigot - Depth H Air Outlet Spigot - Width J Flue Diameter K Rear Return/Fresh Air Inlet - Width L Rear Return/Fresh Air Inlet - Height M Left/Right Return Fresh Air Inlet - Height N Left/Right Return Fresh Air Inlet - Width P Rear of Heater to Air Outlet Spigot* Model 015/020/030 040 050 060/070/080 0100 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) 724 29 857 34 1740 69 1396 55 373 15 840 33 476 19 648 26 178 7 648 26 178 7 457 18 781 31 401 16 857 34 857 34 1930 76 1498 59 474 19 973 38 476 19 781 31 178 7 781 31 178 7 560 22 781 31 401 16 857 34 1016 40 1930 76 1657 65 474 19 973 38 610 24 781 31 178 7 781 31 178 7 560 22 940 37 426 17 1016 40 1676 66 1930 76 2483 98 639 25 1132 45 1238 49 940 37 229 9 1016 40 1994 79 1930 76 2800 110 639 25 1132 45 1524 60 940 37 229 9 NA NA 229 9 560 22 1600 63 96 4 229 9 560 22 1918 76 96 4 NOTE: *For Models 060-0100, the circular flue spigot is at the front of the heater, with the rectangular air outlet spigot at the rear. COMBAT® external cabinet heaters are designed to be sited externally, with heat ducted into the building. These models are fitted with a special metal rain drip cover, and all cabinet joints are silicone sealed to ensure that the heaters are weatherproof. 6 SECTION 4: SPECIFICATIONS 4.3 Air Outlet and Flue Arrangements 4.3.1 Vertical and Horizontal Heaters - Free Blowing (top view) 040 030 015/020 165 165 0100 060/070/080 050 229 203 184 284 NOTE: Models 015-020 are fitted with 229 mm (9") diameter discharge heads as standard. Models 030-0100 are fitted with 356 mm (14") diameter discharge heads as standard. 4.3.2 Vertical and Horizontal Heaters - Air Outlet Spigots (top view) 015/020/030 050 040 100 343 L 38 K 38 38 100 100 343 060/070/080 368 L 38 K 38 38 38 K 100 K 38 0100 K 38 38 100 L L 38 38 38 38 38 L 400 432 Outlet Spigot Dimensions K Spigot width L Spigot Depth Model 015/020/030 040 050 060/070/080 0100 mm (in) mm (in) 648 26 476 19 781 31 476 19 781 31 610 24 940 37 1238 49 940 37 1524 60 7 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.4 General Technical Data Table (all models) Appliance Category II 2H/L 3B/P Model 015 020 030 Electrical Supply* Main Fan Motor Type Motor Size (kW) Motor Pulley (PCD) NA Fan Pulley (PCD) NA 040 050 060 230 V / 50 Hz / 1 Ø Direct Drive Start Current Run Current Airflow Free Blowing 0.75 (Amps) (Amps) (m3/h) (ft3/min) 24 5.3 3398 2000 2.2 24 5.3 3398 2000 28 6.3 5097 3000 21 6.2 6796 4000 21 6.2 8495 5000 1.5 2Ax 80 mm 2Ax 180 mm 10.2 3.5 11044 6500 070 080 400 V / 50 Hz / 3 Ø Belt Drive 2.2 2 A x 95 mm 2Ax 180 mm 30 5.1 12443 7500 2Ax 180 mm 30 5.1 12443 7500 0100 4.0 2Ax 106 mm 2Ax 180 mm 35 9.6 17330 10200 NOTE: *Models 40 & 50 are available with 230 V 1 Ø electrical supply as an extra cost option. A permanent uninterrupted electrical supply is required for all models. When reading the following data tables, ensure that you are using the correct table for the burner and gas valve installed. The data tables include a burner reference letter that can be found on the heater data plate. Refer to the burner manufacturer’s instructions and the specific instructions supplement where applicable. The burner settings shown in the instructions must be used for burner settings. 4.5 Technical Data - Ecoflam ON/OFF Burners (all models - burner reference "C") Model Gross Heat Input Net Heat Input Heat Output Pressure Switch Setting Flue Static Pressure Gas Connection (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (mbar) (mbar) (in) 015 020 030 040 050 060 070 080 0100 55.5 189.4 50.0 170.6 47.4 161.7 73.3 250.1 66.0 225.2 61.2 208.8 93.2 318.0 84.0 286.6 78.4 267.5 4.5 -0.09 129.9 443.2 117.0 399.2 110.2 376.0 4.0 -0.30 162.0 552.7 146.0 498.2 134.5 458.9 6.5 -0.05 208.0 709.7 187.4 639.4 177.7 606.3 5.0 -0.25 242.0 825.7 218.0 743.8 205.3 700.5 6.5 -0.17 1 1/4" 275.2 939.0 248.0 846.2 230.4 786.1 7.5 0.10 348.5 1189.1 314.0 1071.4 293.4 1001.1 7.0 0.45 1.5 -0.05 -0.05 3/4" Natural Gas (G20) Data - Inlet Pressure 20 mbar (7.8 in WG) Min 17 mbar (6.8 in WG) Max 25 mbar (10 in WG) Main Burner Gas Pressure Start Gas Pressure Gas Rate Start Gas Orifice Burner Type Burner Head Burner Head Setting Air Setting mbar mbar (m3/h) (ft3/h) (mm dia) (mm) Valve Type Main Gas Valve Type Start Gas 4.0 NA 5.3 187 2.7 NA 7.0 247 AZUR 60 BLU 120 S S 0 10 2.6 4.2 MBDLE 405 NA 4.2 NA 8.9 314 BLU 120 S 11 6 4.8 1.8 12.4 438 5.0 BLU 170 S 15 2.2 MBDLE 407 7.7 2.8 15.4 546 6.0 BLU 250R S 14 3.5 5.2 7.1 0.9 1.1 19.8 23.1 701 816 7.0 7.0 BLU 250 BLU 250 S S 24 24 2.9 3.6 MBDLE 410 S.I.T. 0 832 051 9.5 1.7 26.2 928 7.0 BLU 250S S 24 1.4 10.0 3.4 33.2 1175 BLU 350 S 21 1.6 MBDLE 412 LPG Gas Propane (G31) Data - Inlet Pressure 37 mbar (14.6 in WG) Min 25 mbar (10 in WG) Max 45 mbar (18 in WG) Main Burner Gas Pressure Start Gas Pressure Gas Rate Start Gas Orifice Main Gas Orifice mbar mbar (m3/h) (kg/h) (mm dia) (mm dia) Burner Type Burner Head Burner Head Setting Air Setting Valve Type Main Gas Valve Type Start Gas (mm) 4.2 NA 2.1 3.9 3.3 NA 2.8 5.1 4.6 NA 3.5 6.5 8.5 AZUR 60 AH S 0 3.0 10.0 BLU 120 AH S 10 4.8 MBDLE 405 NA 10.0 BLU 120 AH S 13 6.6 4.8 1.6 4.9 9.1 5.0 14.5 BLU 170 AH S 15 2.6 MBDLE 407 NOTE: For adjustment of head setting, see Ecoflam Instructions 8 7.5 2.5 6.1 11.3 6.0 14.5 BLU 250R AH S 14 4.5 5.8 7.8 0.8 1.0 7.8 9.1 14.5 16.9 7.0 7.0 14.5 14.5 BLU BLU 250 AH 250 AH S S 24 24 3.1 4.2 MBDLE 410 S.I.T. 0 832 051 12.0 1.5 10.4 19.2 7.0 14.5 BLU 250S AH S 24 1.6 7.6 3.1 13.1 24.3 BLU 350 AH LPG 20 1.8 MBDLE 412 SECTION 4: SPECIFICATIONS 4.6 Technical Data - Ecoflam Modulating Burners (all models - burner reference "H") Model Maximum Gross Heat Input Maximum Net Heat Input Minimum Gross Heat Input Minimum Net Heat Input Maximum Heat Output Minimum Heat Output Pressure Switch Setting Flue Static Pressure Gas Connection (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (mbar) (mbar) (in) 015 020 030 040 050 060 070 080 0100 55.5 189.4 50.0 170.6 38.9 132.7 35.0 119.4 47.4 161.7 33 113 73.3 250.1 66.0 225.2 51.3 175.0 46.2 157.6 61.2 208.8 43 147 1.5 -0.05 93.2 318.0 84.0 286.6 65.2 222.5 58.8 200.6 78.4 267.5 55 188 129.9 443.2 117.0 399.2 90.9 310.2 81.9 279.5 110.2 376.0 77 263 1.0 -0.30 162.0 552.7 146.0 498.2 113.4 386.9 102.2 348.7 134.5 458.9 94 321 208.0 709.7 187.4 639.4 145.6 496.8 131.2 447.7 177.7 606.3 124 423 1.5 -0.25 242.0 825.7 218.0 743.8 169.4 578.0 152.6 520.7 205.3 700.5 144 491 275.2 939.0 248.0 846.2 192.6 657.2 173.6 592.3 230.4 694.0 161 549 2.0 0.10 348.5 1189.1 314.0 1071.4 244.0 832.5 219.8 750.0 293.4 1001.1 205 699 2.5 0.45 -0.05 -0.09 -0.05 -0.17 1 1/4" 3/4" Natural Gas (G20) Data - Inlet Pressure 20 mbar (7.8 in WG) Min 17 mbar (6.8 in WG) Max 25 mbar (10 in WG) Main Burner Gas Pressure Min. Burner Gas Pressure Start Gas Pressure Maximum Gas Rate Minimum Gas Rate Start Gas Orifice Burner Type Burner Head Burner Head Setting Low Flame Air Orange Cam High Flame Air Red Cam Gas Valve Setting Valve Type Main Gas Valve Type Start Gas (mbar) (mbar) (mbar) (m3/h) (ft3/h) (m3/h) (ft3/h) (mm dia) (mm) ** ** 4.9 3.2 NA 5.3 187 2.4 2.8 NA 7.0 247 3.3 2.4 NA 8.9 314 3.8 5.0 6.3 134 177 222 NA NA NA AZUR 60 BLU 120 BLU 120 S S S 0.0 8.0 10.0 20° 13° 22° 33° 40° 80° 0-1, 5 0-1 MBDLE 407 NA 4.1 2.3 1.1 12.4 438 6.7 3.7 1.8 15.4 544 5.2 2.5 0.6 19.8 699 6.7 3.4 0.7 23.1 816 8.0 4.3 0.9 26.2 925 8.6 5.4 1.0 33.2 1172 8.8 311 11.0 388 14.2 501 16.5 583 18.7 660 23.7 837 BLU 170 S 15.0 BLU 250R S 14 18° 32° BLU 250 S 7.0 30° BLU 250 BLU 250 BLU 350 S S S T.O. 22° 25° 35° 55° 60° 30° 0-1, 4 MBDLE 412 S.I.T. 0 832 051 LPG Gas Propane (G31) Data - Inlet Pressure 37 mbar (14.6 in WG) Min 25 mbar (10 in WG) Max 45 mbar (18 in WG) Main Burner Gas Pressure Min. Burner Gas Pressure Start Gas Pressure Maximum Gas Rate Minimum Gas Rate Start Gas Orifice Main Gas Orifice Burner Type Burner Head Burner Head Setting Low Flame Air Orange Cam High Flame Air Red Cam Gas Valve Setting Valve Type Main Gas Valve Type Start Gas (mbar) (mbar) (mbar) (m3/h) (kg/h) (m3/h) (kg/h) (mm dia) (mm dia) (mm) ** ** 4.3 5.7 4.7 2.3 2.9 1.4 NA NA NA 2.09 2.76 3.51 3.87 5.11 6.49 1.46 1.93 2.46 2.71 3.58 4.55 NA NA NA 8.5 10.0 AZUR 60 BLU 120 BLU 120 S S S 0.0 8.0 10.0 20° 13° 22° 33° 40° 80° 0-1, 4 0, 3-0, 9 MBDLE 407 NA 3.1 1.6 1.1 4.89 9.05 3.42 6.34 5.9 2.0 1.7 6.10 11.29 4.27 7.90 5.3 2.3 0.6 7.83 14.49 5.48 10.15 7.2 2.5 0.7 9.11 16.86 6.38 11.80 9.0 3.2 0.7 10.36 19.18 7.25 13.42 6.4 2.0 1.5 13.12 24.29 9.18 17.00 7.0 BLU 170 S 15.0 30° 0-1, 1 BLU 250R S 14 18° 32° 14.5 BLU 250 S NA BLU 250 BLU 250 BLU 350 S S S T.O. 22° 25° 30° 35° 55° 60° 0-1, 4 0-1, 5 0-0, 85 MBDLE 412 S.I.T. 0 832 051 NOTE: The air setting is a guide only. The final setting is subject to combustion testing. When setting the minimum firing rate, a check must be made following the setting of the burner combustion. The check is made by running the heater on low fire for a minimum of 15 minutes at the full transport air rate and at typical ambient conditions. During the test, check that the flue gas temperature does not fall below 125° C. Should the flue gas temperature fall below 100° C, then the low fire gas setting must be increased to a value that will achieve 125° C flue gas temperature; otherwise condensation may form in the heat exchanger and flue, causing rapid corrosion and short operational life. NOTE: For adjustment of head setting, see Ecoflam Instructions. 9 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.7 Technical Data - Ecoflam Oil-Fired Burners (burner reference "G") Model Gross Heat Input Heat Output 015 (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) Burner Type Oil Pump Connections 020 55.5 73.3 189.4 250.1 47.4 61.2 161.8 208.9 Minor 8 030 93.2 318.0 78.4 267.4 Minor 12 (in) 040 050 060 070 080 0100 129.9 162.0 443.2 552.7 110.2 134.5 375.9 458.8 Minor 20 3/8 208.0 709.7 177.7 606.5 242.0 825.7 205.3 700.3 Minor 30 275.2 939.0 230.4 786.2 348.5 1189.1 293.4 1001.0 Major 30 2.50 4.00 5.00 5.00 7.00 (fixed) 1.8 11.0 160 32.44 7.14 Light Fuel Oil (Gas Oil) Data Nozzle Size Angle & Type Make Head Setting Air Setting Burner Fuel Pressure Fuel Consumption Maximum Oil Pressure to Pump Inlet *US (gal/h) 1.00 1.50 0 8.5 10.3 150 6.82 1.50 1.75 60S Danfoss 14 5.5 12.4 180 8.68 1.91 3.50 60A Delavan (mm) (number) (Bar) (lbf/in2) (L/h) *UK (gal/h) (Bar) (lbf/in2) 8 4.2 12.1 175 5.17 1.14 *US (gal/h) 1.25 1.75 2.50 3.00 4.00 60S Danfoss (mm) (number) (Bar) (lbf/in2) (L/h) *UK (gal/h) 8 4 8.6 125 5.47 1.20 0 6.6 9.7 140 7.23 1.59 14 6 8.3 120 9.19 2.02 3 9.7 140 12.81 2.82 4 8.3 120 15.98 3.51 3 11.7 170 12.09 2.66 4 10.0 145 15.08 3.32 (full back) 3.7 11.0 160 19.36 4.26 4 10.0 145 22.53 4.96 6.2 13.0 188 25.62 5.63 5.00 6.00 6.50 (full back) 3.7 9.0 130 20.52 4.51 4.5 8.3 120 23.87 5.25 6 9.3 135 27.14 5.97 .21 3 Kerosene Data Nozzle Size Angle & Type Make Head Setting Air Setting Burner Fuel Pressure Fuel Consumption NOTE: For adjustment of head setting, see Ecoflam Instructions. * Nozzle sizes are quoted in US gal/h. Fuel consumption is quoted in imperial gal/h. 10 8.50 60B (fixed) 1.4 8.3 120 34.37 7.56 SECTION 5: HEATER INSTALLATION SECTION 5: HEATER INSTALLATION 5.1 General Heaters are designed for floor standing vertical installation. Special versions supplied with steel channels to support the heater are available and may be mounted horizontally. When installed horizontally, the heater will normally lie on its left side when viewed from the burner. The heater should be placed on a firm, level, non-combustible surface that can support its weight. See Page 5, Section 4.1 for weight details. 5.2 Handling All cabinet heaters are supplied secured to a wooden pallet and shrink wrapped. Use the pallet to support the heater during handling and installation. Figure 2: Typical Installation of a Gas Fired Cabinet Heater 1m Minimum Flues up to 200 mm dia. are fitted with Bird Screens, over 200 mm with a Rain Cap. Lead Roof Plate Flue Air Distribution Heads Roof Building Ventilation Gas Isolating Valve Electric Supply Union Connection 11 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 3: Typical Installation of a Oil-Fired Cabinet Heater 1m Minimum Flues up to 200 mm dia. are fitted with Bird Screens, over 200 mm with a Rain Cap. Lead Roof Plate Flue Air Distribution Heads Gauge Vent Filler Building Ventilation Fusible Link Electric Supply Fuel Tank Fire Valve Gate Valve Plugged Drain Valve 12 Roof Manual Isolating Valve Fuel Filter SECTION 6: FLUE INSTALLATION SECTION 6: FLUE INSTALLATION 6.1 Flue Installation WARNING Fire Hazard Some objects will catch fire or explode when placed close to heater. Keep all flammable objects, liquids and vapours the required distance away from the heater. Figure 6 through Page 14, Figure 9. The joints between the flue and the roof or wall must be properly sealed. If the flue passes through a wall or ceiling of combustible material it must be enclosed by a sleeve of non-combustible material and be separated from the sleeve by at least a 25 mm air gap. Flues must be adequately supported so that the heater does not bear the weight of the flue. For straight and offset flue termination See Page 13, Figure 4 and Figure 5. Flues must be correctly sized for the model. See Page 5, Section 4.1. Flues should be assembled as on Page 13, Figure 4 and Figure 5 and Page 14, 90° bends and horizontal pipe must not be used in flues except for the immediate connection to horizontally mounted heaters (1 m max). 135° bends are used to offset the flue as in Figure 5. If condensation is likely to occur in the flue, then provision should be made for drainage. Figure 4: Flue Termination Figure 5: Offset Flues with 135° bends Failure to follow these instructions can result in death, injury or property damage. Flues up to 200 mm dia. are fitted with Bird Screens, over 200 mm with a Rain Cap. 1m Minimum above roof *1 m Minimum Nearby Structure 1m Minimum Minimum Total 1m + (0.5m for each 135° bend) + (1m for each 0.33m of flue running in the 135° direction) Roof Use adequate support to prevent heater from carrying the weight of the flue. *Less than 2.5 m Roof Use adequate support to prevent heater from carrying the weight of the flue. Wall 135° *If the point of roof intersection is within 2.5 m of a nearby structure, the flue must terminate at least 1 m above that structure. Wall 13 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 6: Guy Wire Figure 8: Flue and Roof Detail Screws, four typical. Over 2 m use Guy Wires Roof Clamp ring Roof Rain Collar Seal Rain Collar joint with high temperature silicon sealer Heat Sealed Flash Band Wall Use adequate support to prevent heater from carrying the weight of the flue. Secure Bolts Screws Stainless Steel Roof Tidy Plate Figure 9: Flue and Heater Spigot Joint Detail Figure 7: Socket Direction If it is necessary to cut any section of flue, the cut is made at the bottom of the lowest section where it connects to the heater. Flue Terminal Male spigot facing up. Roof Plate Masterflash Soaker Flashing or Rain Collar. Screws Tidy Plate Roof Fire Cement Metal Sleeve Conversion Collar last joint below the roof line. Clamp Ring 14 Screws, four typical. Male spigot facing down. Heater Spigot Heat Resistant Rope SECTION 7: AIR SUPPLY SECTION 7: AIR SUPPLY 7.1 Air Supply It is important to ensure adequate air supply at all times for both combustion and heating requirements in accordance with BS 6230 for UK installations and the latest revisions of applicable standards and local and national codes. 7.2 Isolated Equipment Rooms Ventilation must prevent the temperature of isolated equipment room from exceeding 32°C as well as prevent any negative air pressure within the room. Any isolated equipment room containing air heaters will require permanent air vents direct to outside air in compliance with local codes. Where natural ventilation is used, suitable permanent openings at low and high levels, communicating directly with the outside air, must be provided. Where mechanical ventilation is used, extract rate must be 5% - 10% less than the inlet rate. The mechanical ventilation must be interlocked with the burner on the heater. The main fan requires a minimum free air return path of 1 m2 per 197 kW of heater output or 0.33 m2, whichever is greater. NOTE: When heaters are installed in the horizontal mode and connected to distribution ducting and/or inlet ducting, then the natural convected air flow through the heater, before the main fan turns on may be disrupted. To ensure correct operation of the fan under these circumstances, in all COMBAT® cabinet heaters designed for horizontal mounting, the main fan will operate in conjunction with the burner sequence by the use of a time delay or direct acting relay. It is strongly recommended that when any heater is connected to installation ducting, a similar approach to the fan control is used. Any such control must be in parallel with the fan thermostat so that the fan "run on" feature is still able to operate (See Page 22, Section 9.5). 7.2.1 Heaters Installed Within the Heated Space Where the volume of the heated space is greater than 4.7 m3 per kilowatt of total rated heat input and the air change rate is at least 0.5/h, additional high and low level ventilation will not be required. For a building having an air change rate less than 0.5/h, ventilation will be necessary in accordance with local and national codes. 7.3 Building Ventilation Where ventilation is required, air must be taken from an outside point where it is not likely to be contaminated or obstructed. 7.4 Distribution Ducting Duct should be full size for at least twice the minor dimension before change of direction or reduction of area. 7.5 Return Air Ducting In installations employing recirculation or fresh air ducting, this ducting shall comply with the following: 1. There shall be an unobstructed air path connected directly to the heater. 2. The return air or fresh air shall be connected by ducting directly to the air inlet on the heater. 3. Where automatic or manual dampers are provided for operational adjustment in these ducts, they shall be proved in the correct position during the operation of the burner. 15 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 8: FUEL PIPING 8.1 Connections Connect the heater to the gas supply, ensuring that the final connections are as follows: • Gas supply pipe is run in medium or heavy gauge tubing in compliance with local and national codes. • The gas supply pipe is adequately sized to carry the total volume of gas for the complete installation. • An isolating valve and union connection should be used and fitted into the supply adjacent to the heater. WARNING Fire Hazard Connect gas supply according to Figure 10. Gas can leak if not installed properly. Failure to follow these instructions can result in death, injury or property damage. It is important that the gas supply pipe and the electrical connections do not support any of the heater’s weight. A gas meter is connected to the service pipe by the Gas Supply Company. Any existing meter should be checked, preferably by the company, to ensure that the meter is adequate for the rate of gas supply required. Installation pipes must be fitted in accordance with local and national codes. Pipe work from the meter to the heater(s) must be of adequate size. Pipes of smaller size than the heater inlet gas connection should not be used. IMPORTANT - The complete installation must be purged and tested for gas soundness in accordance with local and national codes. Figure 10: Gas Connection Medium or Heavy Gauge Tubing Gas Connector Gas Isolating Valve Union Connection Drip Leg 16 SECTION 8: FUEL PIPING 8.2 Fuel Oil Supply 8.2.1 Fuel Storage Tank The fuel storage tank should be located outside the building as close as possible to the heater. The tank must be installed per local and national codes. 8.2.4 B. M. Oil Lifter Where a gravity feed system cannot be used, a B. M. oil lifter may be used for small installations up to the equivalent of a single model 050 on minimum lift or a single model 020 on maximum lift. The fuel output from the oil lifter is gravity fed. The B. M. oil lifter requires a constant 230 V 50 Hz 1 Ø electrical supply. The maximum pipe size to be used on the suction side is 1/4" ID, 5/16" OD (8 mm). For maximum loading of oil lifters See Page 17, Figure 11. Consult the manufacturer’s information regarding the need to prime these devices. 8.2.2 Fuel Pipes The fuel pipes must be sized to ensure an adequate supply of oil to the entire installation. Galvanised pipe must not be used for oil installations. The fuel pipe must terminate at each heater with an isolating manual valve, a fire valve and a fuel filter. See Page 12, Figure 3. The fusible link of the fire valve should be installed 100 mm (4 in) above the burner. The heater’s oil burner pump inlet is provided with a flexible oil line which should be used for the final connection. When making the final connection to the heater, do not block any of the removable panels of the heater. All COMBAT® oil-fired cabinet heaters are supplied with burner pumps fitted for one pipe systems. 8.2.5 Pressurised Systems See Page 18, Figure 12. For larger installations, a pressurised system may be used. In this type of system the pump draws fuel from the tank, then pushes it through the installation under pressure. The pressure is controlled at the pump by a pressure relief valve at approximately 0.8 BAR (12 psi). When a presurised system is used, a pressure reducing valve set at approximately 0.3 BAR (5 psi) should be installed on the fuel inlet to each heater after the manual isolating valve. This protects the oil pump from the danger of possible over pressure under fault conditions. The electrical supply for the pump installation will depend upon the type of pumps chosen, but will normally be set to run continuously. 8.2.3 Gravity Feed Systems The simplest installation is a gravity feed system. This system relies on the head of the fuel to push the fuel through the system. See Page 12, Figure 3. Figure 11: B. M. Oil Lifter 6 20 15 10 5 240 V Oil Lifter 0 Flow Output - UK gal/h Flow Output - L/h 25 Total Suction Length in Feet 8mm (5/16”) O.D. Copper Tube 5 4 33’ 65’ 99’ 132’ 165’ 3 2 1 0 0 5 10 15 20 25 Lift in Feet Oil Heater Air Vent Filler Pipe Max 8m Min 0.15m Max 3m Min 0.15m 0 1 2 3 4 5 6 7 8 Lift in Metres Technical Data Maximum Lift............. 8m Maximum Capacity.... 20 L/h Actual Capacity.......... 10 - 20 L/h Dependant upon vertical lift and suction line length. Storage Tank 50 mm 17 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 12: Pressurised System Installation - Duplex System Pressure Gauge Relief Valve Check Valve Check Valve Stop Valve Stop Valve For Fuel Tanks above Pump Set No. 1 Pump Stop Valve Pressure Reducing Valve No. 2 Pump Stop Valve Burner Duplex Pump Set Check Valve Storage Tank Below Ground (The system shown has one pump for run and the other for standby. The valves allow the standby pump to be removed for maintenance while the system is still running). 18 Pressure Reducing Valve Burner SECTION 9: WIRING AND ELECTRICAL INFORMATION SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.1 Electrical Supply 9.2.2 Positioning Room Thermostats or Roberts-Gordon Control A 230 V 50 Hz 1 Ø supply is required for all heater Models 015 to 030 connected to the heater terminals A room thermostat or Roberts-Gordon control L1, N and Earth. should be mounted on a wall or column at a height of approximately 1.5-1.8 metres from the floor to Standard models 040 to 0100 and all High Flow measure the ambient temperature. It should be clear models require a 400 V 50 Hz 3 Ø and neutral of both cold draughts and the direct path of warm air supply connected to the heater terminals L1, L2, L3, from the heater. N and Earth. 9.2.3 Remote Frost Thermostat All heaters and controls must be correctly earthed. All external wiring must comply with the relevant IEE When required, connect to terminals 2 and 3 in the main terminal block. and local regulations and be carried out by a Locate the thermostat within the heated space qualified electrician. adjacent to the most vulnerable equipment that requires protection. It is important that "L and N" polarity is correct for these heaters, as incorrect polarity may prevent the See Page 20, Section 9.3 through Page 27, Section burner control box from operating properly. It is also 9.10. important that the voltage between N and earth is at 9.2.4 Controls for High/Low Burner Operation 0 V and can never exceed 15 V. For heaters with a high/low burner, the controls will An isolator with a contact separation of at least 3 need to provide two stage signal to operate these mm on all poles should be installed adjacent to the burners. This is best provided by a two stage heater, but not attached to it, to disconnect all thermostat. supplies to the heater and where necessary to The thermostat may control the heater outlet isolate the remote control panel. temperature if the heater is designed for a duct distribution system or the room temperature. The final connection to the heater should be made in The site wiring will be across terminals 2 and 3 for metal sleeved flexible cable or flexible conduit to the any time control and the on/off function of the burner main terminal block under the front lower panel of (stage two), and across terminals 7 and 8 for the the heater using 1 sq. mm cable. Model 0100 and high fire (first stage) setting. High Flow models with 5.5kW or 7.5kW motors use 1.5 sq. mm cable. Cable entry is provided into the The burner will then operate as follows: rear horizontal frame of the cabinet. Temp. from cold up to the 1st set point ..................... Full fire at max. rate Temp. above 1st set point up to 2nd set point................. Low fire at min. rate Temp. above 2nd set point ...............................Off. WARNING Electrical Shock Hazard Disconnect electrical power before servicing. Failure to follow these instructions can result in death or electrical shock. 9.2 Remote Controls The heater is designed to be operated by controls installed remotely from the heater. See Page 20, Section 9.3. through Page 27, Section 9.10. 9.2.1 Burner Controls (Thermostat) Controls to operate the burner must be voltage free contacts connected between terminals 2 & 3 of the main terminal block. 9.2.5 Controls for Fully Modulating Burners For heaters that incorporate a fully modulating burner, a special temperature control is provided with the heater. On-site wiring of the temperature sensor is required with any time control. The heater will normally be controlled by the temperature of the air in the outlet duct, but it is possible to control on room temperature. The position of the sensor in the outlet duct is determined on site. Using a themometer, select a position in the outlet duct approximately 1 m from the heater, across the cross section of the duct that provides a reasonable average of the temperatures found. Mount the sensor at this position for best results. When operating at reduced heat input, the leaving air temperature may be low when controlled on room temperature. The time control and any other on/off controls will be across terminals 2 and 3. The sensor will be connected to terminals 8 and 9. The operation will occur in the following sequence: 1. The burner will fire. When the burner sequence reaches the release to modulation stage, the control will begin to monitor the outlet temperature. 19 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 2. The control will then adjust the burner input continuously to attempt to maintain the temperature set on the control. 3. If the temperature continues to rise with the burner operating at minimum fire, the control will turn off the burner until the temperature falls again, and the burner will restart. If a switch is required to turn on the main fan for ventilation, this must be voltage free, from external sources, and may be connected between terminals L1 & 1 for models 015 to 030 and terminals 2 & 1 for all other models. 9.3 CCH Wiring Diagram Gas Models 15-30 (floor standing) L1 L1 N N T1 T1 GAS BURNER 7 WAY PLUG Blue Red / White T2 S3 B4 T2 B4 S3 PACKAGED BURNER FAN / LIMIT STAT Red / White FAN LIMIT 4 3 2 Red / White Red TIME/TEMPERATURE CONTROLS Red / White Note: Remote fan control carries full load of fan motor 7 amp inductive Red / White 10 A FAN CONTROL 1 Red L1 L2 230 V 50 Hz 1 PH SUPPLY MAIN FAN MOTOR L3 N Brown Blue Blue 1 mm2 Ø Red Tri Rated Flex Cable MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 20 SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.4 CCH Wiring Diagram Oil Models 15-30 (floor standing) L1 L1 N N T1 T1 OIL BURNER 6 WAY PLUG T2 S3 Blue Red / White T2 S3 PACKAGED BURNER FAN / LIMIT STAT Red / White FAN LIMIT 4 3 2 Red / White Red TIME/TEMPERATURE CONTROLS Red / White Note: Remote fan control carries full load of fan motor 7 amp inductive Red / White 10 A FAN CONTROL 1 Red L1 L2 230 V 50 Hz 1 PH SUPPLY MAIN FAN MOTOR L3 N Brown Blue Blue 1 mm2 Ø Red Tri Rated Flex Cable MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 21 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.5 CCH Wiring Diagram Gas Models 15-30 (horizontal mounting) L1 L1 N N GAS BURNER 7-WAY PLUG FOR GAS BURNER T1 IS NOT USED B4 = BURNER RUN TO R1 COIL ALL OTHER WIRES SAME AS OIL BURNER B4 REMOTE LOCKOUT RESET 7 Red / White 8 3 Red / White Blue Red / White 6 N 7 2 1 Red / White T2 S3 R1 COIL 240v Red / White T2 S3 OUTPUTS LOCKOUT RESET SIGNAL FROM BURNER RUN SIGNAL BURNER B4 LOCKOUT SIGNAL Blue T1 T1 PACKAGED BURNER 5 REMOTE LOCKOUT LAMP 230V FOR BURNERS WITH LANDIS & STEFA CONTROL BOX (GAS-FIRED) FAN / LIMIT STAT Red / White LIMIT 4 3 TIME/TEMPERATURE CONTROLS Red / White 10 A 2 Red / White 1 FAN CONTROL (OPTIONAL) Brown L1 Red 1 mm2 Ø RED TRI RATED FLEX CABLE L2 230 V 50 Hz 1 PH SUPPLY MAIN FAN MOTOR L3 N Blue Blue MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 22 Red Red / White FAN SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.6 CCH Wiring Diagram Oil Models 15-30 (horizontal mounting) L1 L1 OIL BURNER 6-WAY PLUG PACKAGED BURNER N R1 COIL 240v 7 Red / White REMOTE LOCKOUT RESET 3 6 N 1 Red / White Red / White Red / White 8 7 2 Red / White T1 T2 Blue S3 T1 OUTPUTS LOCKOUT RESET SIGNAL FROM LOCKOUT SIGNAL BURNER S3 BURNER RUN SIGNAL T2 N Red / White 5 REMOTE LOCKOUT LAMP 230V FOR BURNERS WITH SATRONIC CONTROL BOX (OIL-FIRED) FAN / LIMIT STAT Red / White LIMIT 4 3 TIME/TEMPERATURE CONTROLS Red Red / White FAN Red / White 10 A 2 Red / White 1 FAN CONTROL (OPTIONAL) Brown L1 Red 1 mm2 Ø RED TRI RATED FLEX CABLE L2 230 V 50 Hz 1 PH SUPPLY MAIN FAN MOTOR L3 N Blue Blue MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 23 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.7 CCH Wiring Diagram Gas Models 40-50 (floor standing) L1 L1 GAS BURNER 7-WAY PLUG Red / White N T1 S3 T2 Red / White Red / White TIME/TEMPERATURE CONTROLS LIMIT FAN B4 B4 S3 BURNER T1 PACKAGED T2 N FAN / LIMIT STAT Red / White 4 Red / White 3 10 A Red / White 2 1 FAN CONTROL Red L1 CONTACTOR Red / White L2 400 V 50 Hz 3 PH SUPPLY L3 Red MAIN Red Black Red Brown Grey N C1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 24 FAN MOTOR SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.8 CCH Wiring Diagram Oil Models 40-50 (floor standing) L1 L1 OIL BURNER 6-WAY PLUG Red / White TIME/TEMPERATURE CONTROLS LIMIT FAN Red / White S3 BURNER S3 PACKAGED Red / White T1 T2 N T1 T2 N FAN / LIMIT STAT Red / White 4 Red / White 3 10 A Red / White 2 1 FAN CONTROL Red L1 CONTACTOR Red / White L2 400 V 50 Hz 3 PH SUPPLY L3 Red MAIN Red Black Red Brown Grey N FAN MOTOR C1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 25 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.9 CCH Wiring Diagram Gas Models 40-50 (horizontal mounting) FOR GAS BURNER T1 IS NOT USED B4 = BURNER RUN TO R1 COIL ALL OTHER WIRES SAME AS OIL BURNER L1 L1 GAS BURNER 7-WAY PLUG T1 N T1 N T2 B4 S3 OUTPUTS LOCKOUT RESET SIGNAL FROM BURNER BURNER RUN SIGNAL T2 LOCKOUT SIGNAL B4 S3 PACKAGED BURNER Red / White R1 COIL 240v 8 REMOTE LOCKOUT RESET Red / White Blue 2 7 3 1 7 Red / White 5 REMOTE LOCKOUT FOR BURNERS WITH LANDIS & STEFA LAMP 230V CONTROL BOX (GAS FIRED) Red / White N Red / White 6 FAN / LIMIT STAT Red / White LIMIT 4 3 TIME/TEMPERATURE CONTROLS Red / White 2 FAN CONTROL (OPTIONAL) Red / White Red / White FAN Red / White 10 A 1 Red L1 L2 400 V 50 Hz 3 PH SUPPLY L3 N CONTACTOR Red / White Red Red Black Brown Grey Red Blue R1 Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 26 MAIN FAN MOTOR SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.10 CCH Wiring Diagram Oil Models 40-50 (horizontal mounting) L1 L1 OIL BURNER 6-WAY PLUG PACKAGED BURNER T2 S3 T1 N T2 OUTPUTS LOCKOUT RESET SIGNAL FROM BURNER LOCKOUT SIGNAL S3 BURNER RUN SIGNAL T1 N Red / White R1 COIL 240v 8 7 3 1 7 Red / White 5 Red / White 6 Red / White REMOTE LOCKOUT FOR BURNERS WITH RESET SATRONIC CONTROL BOX (OIL FIRED) REMOTE LOCKOUT LAMP 230V N Red / White Red / White 2 FAN / LIMIT STAT Red / White LIMIT 4 3 TIME/TEMPERATURE CONTROLS Red / White 2 FAN CONTROL (OPTIONAL) Red / White Red / White FAN Red / White 10 A 1 Red L1 L2 400 V 50 Hz 3 PH SUPPLY L3 N CONTACTOR Red / White Red Red Black Brown Grey Red Blue MAIN FAN MOTOR R1 Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 27 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.11 CCH Wiring Diagram Gas Models 60-100 (floor standing) L1 L1 GAS BURNER 7-WAY PLUG Red / White N T1 T2 4 Red / White 3 Red / White Red / White Red / White TIME/TEMPERATURE CONTROLS LIMIT FAN B4 S3 T1 B4 S3 PACKAGED BURNER T2 N FAN / LIMIT STAT 10 A Red / White 2 1 Red FAN CONTROL L1 CONTACTOR Red / White L2 400 V 50 Hz 3 PH SUPPLY L3 Red MAIN Red Black Red Brown Grey N R1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 28 FAN MOTOR SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.12 CCH Wiring Diagram Oil Models 60-100 (floor standing) L1 L1 OIL BURNER 6-WAY PLUG Red / White N Red / White TIME/TEMPERATURE CONTROLS LIMIT FAN 4 Red / White 3 Red / White Red / White T1 T2 S3 T1 S3 PACKAGED BURNER T2 N FAN / LIMIT STAT 10 A Red / White 2 1 Red FAN CONTROL L1 CONTACTOR Red / White L2 400 V 50 Hz 3 PH SUPPLY L3 Red MAIN Red Black Red Brown Grey N FAN MOTOR R1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 29 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.13 CCH Wiring Diagram Gas Models 60-100 (horizontal mounting) FOR GAS BURNER T1 IS NOT USED B4 = BURNER RUN TO R1 COIL ALL OTHER WIRES SAME AS OIL BURNER L1 L1 T1 N T1 N T2 T2 S3 S3 B4 B4 GAS BURNER 7-WAY PLUG Red / White PACKAGED BURNER LOCKOUT SIGNAL OUTPUTS LOCKOUT RESET SIGNAL FROM BURNER RUN SIGNAL BURNER Blue Blue Red / White R1 COIL 240v 7 2 Red / White 3 1 8 REMOTE LOCKOUT RESET 7 5 REMOTE LOCKOUT FOR BURNERS WITH LANDIS & STEFA LAMP 230 V CONTROL BOX (GAS-FIRED) Red / White N Red / White 6 FAN / LIMIT STAT Red / White 4 TIME/TEMPERATURE CONTROLS 3 Red / White Red / White 2 FAN CONTROL (OPTIONAL) LIMIT Red / White Red / White FAN 10 A 1 Red L1 400 V 50 Hz 3 PH SUPPLY L2 L3 N CONTACTOR Red / White Red Red MAIN Black Brown Grey Red R1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 30 FAN MOTOR SECTION 9: WIRING AND ELECTRICAL INFORMATION 9.14 CCH Wiring Diagram Oil Models 60-100 (horizontal mounting) L1 L1 T1 N T1 N T2 T2 S3 S3 OIL BURNER 6-WAY PLUG Red / White PACKAGED BURNER BURNER RUN SIGNAL OUTPUTS LOCKOUT RESET SIGNAL FROM LOCKOUT SIGNAL BURNER Blue Red / White R1 COIL 240v Red / White 7 2 Red / White 3 1 8 7 6 5 Red / White Red / White REMOTE LOCKOUT FOR BURNERS WITH RESET SATRONIC CONTROL BOX (OIL-FIRED) REMOTE LOCKOUT LAMP 230V N FAN / LIMIT STAT Red / White 4 TIME/TEMPERATURE CONTROLS 3 Red / White Red / White 2 FAN CONTROL (OPTIONAL) LIMIT Red / White Red / White FAN 10 A 1 Red L1 400 V 50 Hz 3 PH SUPPLY L2 L3 N CONTACTOR Red / White Red Red MAIN Black Brown Grey Red FAN MOTOR R1 Blue Blue 1 mm2 Ø RED TRI RATED FLEX CABLE MAIN TERMINALS IN CONTROL PANEL NOTE: Any of the original wire supplied with the heater must be replaced with wiring material having a temperature rating of at least 105°C and 600 V. 31 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 9.15 Final Connections to Ecoflam HIGH/LOW or Modulating Burners (all models) 32 SECTION 10: COMMISSIONING SECTION 10: COMMISSIONING Installation, service, commissioning and annual inspection of the heater must be done by a contractor qualified in the installation and service of gas or oil-fired heating equipment. Read this manual carefully before installation, commissioning, operation or service of this equipment. WARNING 2. Check the correct fuse size is fitted in the local supply isolator. See Page 8, Section 4.4. 10.1.3 Polarity Test - 1 Ø L N V 230v 50Hz AC V 0v (must be less than 15v) Supply Earth Terminal Electrical Shock Hazard Less Than 0.1 ohm Use extreme caution while commissioning. Failure to follow these instructions can result in death or electrical shock. 10.1 Pre-Commission Checks All pre-commission checks must be carried out before lighting the heater. Ensure that the heater and all controls are suitable for the fuel, pressure and electrical supply to which they are to be connected. 10.1.1 Louvers Where fitted, the air delivery louvers need to be set during commissioning to give the required air distribution. WARNING Cut Hazard Turn off fuel and electrical supply before maintenance. Fan can start automatically at any time. Failure to follow these instructions can result in severe injury or product damage. 10.1.2 Electrical Checks All pre-commission checks must be carried out before commissioning the heater. 1. Check that all site wiring is connected in accordance with the appropriate wiring diagrams on Page 20, Section 9.3 through Page 32, Section 9.15. ohm 10.1.4 Polarity Test - 3 Ø Voltage between each phase L1, L2 and L3 and Earth or Neutral should be approximately 230 V. Voltage between any 2 phases should be approximately 400 V. Test Neutral to Earth as single phase. 10.1.5 Fan Rotation Check Switch on the electricity supply at the isolator and the manual switch to "fan on" (if no remote fan switch is installed, press the white button on the fan/limit thermostat). On 3 Ø heaters, check the rotation of the main fan. Rotation should be clockwise looking at the drive end. If rotation is not correct, turn off the isolator and change over any two of the incoming supply phases and recheck. It will be necessary to remove the lower front or right side panel to see fan rotation. 10.1.6 Fan Motor Overload Check On 3 Ø belt drive heaters, check the correct settings of the fan motor overload. This should be 0.2 A above the rated current on the heater data plate. See Page 8, Section 4.4. 10.1.7 Mechanical Checks 1. Check that the flue is installed in accordance with these instructions and local regulations. 2. Check that the settings of the Combination Fan/ Limit thermostat are correct - See Page 34, Figure 13. 33 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 13: Combination Thermostat (all models) 100 0 12 60 80 Set Point 3 Limit Set to 110°C Set Point 1 Fan Off Set to 38°C C° 20 40 Set Point 2 Fan On Set to 60-65°C See Page 34, Section 10.2.5 and repeat until the burner fires. 10.2.4 Initial Setting NOTE: Skip this step for models 015 to 030. Once firing, the start gas pressure should be set to the value given in the Data Tables for the burner type and the model concerned (see the burner reference letter on data plate). This is carried out by turning the governor adjusting screw (accessed under the black push-on cover) clockwise to increase pressure, or counter clockwise to decrease pressure. 10.2.5 Set Gas Rate 1. Switch off and refit the main gas valve plug (removed earlier to allow the main gas valve to operate). 2. Switch on again and allow the burner to fire and to settle for a few minutes. 10.2.1 Gas Supply 3. Adjust the main gas burner pressure to the All aspects of the gas installation, including the gas meter, must be inspected, tested for soundness and value given in the relevant Data Table for the purged in accordance with local and national codes. model concerned using the Main Gas RegulaEnsure that the air is fully purged from the heater tor (accessed under the swivel cover). See inlet pipe up to the main gas valve inlet test nipple. Page 37, Figure 17. 10.2.2 Before Operating the Heater The results of setting the gas flow rate by using burner pressure only can lead to quite wide Ensure the burner head, air damper and pressure switch settings are adjusted for the correct burner in variations in heat input due to the nature of the accordance with the Data Tables on Page 8, Section burners used. 4.4 through Page 10, Section 4.7 (see the burner NOTE: If the correct burner pressure cannot be reference letter on data plate). reached, then check the inlet pressure to the valve, To ensure that all the controls are in safe working with the burner firing. See Technical Data Tables on order, operate the heater for the first time with the Page 8, Section 4.5 for inlet pressure requirements. isolating gas valve turned off. 1. Turn off the gas isolating valve Do not continue to adjust the regulator if the 2. Using the installed external control, turn on the pressure is not changing. burner. The automatic sequence will now begin If the inlet pressure is too low to allow the correct as described on Page 35, Figure 14. burner pressure setting, then the gas inlet pressure There will be no ignition of the burner and lockout must be corrected before completing the will occur, which proves the controls are operating commissioning. correctly. 10.2 Commissioning the Burner (gas heaters) High/Low and modulating burners have additional specific requirements. Follow the manufacturer’s instructions using the data provided on Page 8, Section 4.4 through Page 10, Section 4.7. 10.2.3 Fire the Burner for Dungs Combination Gas Valves 1. Open the gas isolating valve. 2. Connect a suitable pressure gauge to the burner pressure test point. 3. On models 040 or larger, to ensure that start gas only may pass to the burner, remove the gas valve electrical plug for the main gas valve. 4. Reset the lockout button of the control box and the burner should now fire. If lockout should occur when the start gas valve energises (or the main gas valve for models up to 030), repeat 3 or 4 times. If after several attempts the burner does not fire, then turn the start gas governor adjusting screw (or main gas governor for models 015 to 030) 3 turns clockwise. 34 10.2.6 Check Gas Rate It is important to check that the gas rate set during the commissioning is within ± 5% of the required flow rate. This may be achieved by checking the gas flow to the heater wherever possible by using the gas meter and timing the flow through the meter. The results should be compared with the required flow rate for the model given in the Data Tables, adjusting the burner pressure to correct for any error. Checking the gas rate must be carried out with all other appliances including any pilots, turned off. 1. After burner pressure adjustment, allow the heater to operate for at least 15 minutes and then re-check settings. 2. Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap. SECTION 10: COMMISSIONING 3. Check gas flow rate at gas meter. 10.3 Control - Gas-Fired Heaters For High/Low and modulating burners, follow the general sequence as described below and also have extra functional stages related to air damper positions. Refer to the burner manufacturers instructions for further detail. Gas burners have only one pressure switch, which is configured to cover combustion air and reaction to increases in combustion chamber pressure. NOTE: If the pressure switch contacts (normally closed) are open, the heater will not start. 2. The combustion air fan turns on and the pressure switch contacts close within the next 5 seconds to indicate sufficient combustion air or lockout will occur. 3. The sequence continues with a purge period with the burner fan running. 4. The electrical ignition switches ON at the end of the purge period. 5. The start gas valve opens (main gas valve for 015 - 030) and once a flame has been established, this remains open until close down. The flame probe is now continuously monitoring for the safe presence of flame. 6. Five seconds later, the electric ignition turns off, leaving the start gas flame to be proved as stable. 7. The start gas runs for ten seconds, then the main gas valve opens. The control is now in its normal run position 10.3.1 Description of Gas-Fired Heater Control The gas fired burner fitted to all COMBAT® cabinet heaters is controlled by a full sequence plug-in control. This control ensures the safe start and stop sequence and also monitors the safe presence of a flame and burner air pressure. Models 015 - 030 are wired for direct ignition of the main flame. All other models are wired for ignition of a start gas flame as the first stage and then the main gas flame as the second stage. 10.3.2 Sequence of Operation 1. With the external controls on calling for heat, and the pressure switch at rest, the burner fan will switch on after the control does a "self check". Figure 14: Gas-Fired Heater Control Box Sequence Thermostat Motor Pressure Switch Transformer Gas Valve Ionization Probe + 30 s + 2s 3s Necessary Input Signal Output Signal of the Device 10.3.3 Motor Starter and Thermal Overload On belt-driven models, the motor is controlled by a direct on-line contactor starter fitted with thermal overload protection. If the thermal overload operates, the main fan will not run. To reset, press the reset button on the overload unit. NOTE: For models with a 5.5 kW motor or larger, the direct on-line starter will be replaced by a automatic starter. The overload should be set to indicate approximately 0.2 A above the normal running current of the heater. See Page 8, Section 4.4. 10.3.4 Burners For details of the packaged burners, see the manufacturer’s instructions and Page 8, Section 4.5 through Page 9, Section 4.6. When reading the data tables, ensure that the correct table for the burner and gas valve installed is being used. The data tables are listed under a burner reference letter which can be found on the heater data plate. 35 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 15: Motor Starter (models 040 -100 and Thermal Overload (models 060 - 100) Wire Connecting Overload Switch to Coil Line Connections Contactor Load Connections Thermal Overload Overload Reset Button Overload Connection Overload Scale (motor current amps) Overload Adjusting Level Figure 16: Gas Train Circuit for Dungs Gas Valves (all models) Models 15 to 30 - All types of valve Models 40 to 100 - All types of valve To Burner Automatic Gas Valve & Regulator Gas Inlet TP1 36 Automatic Burner Gas Valves Flange 1 1 To Burner Union Automatic Gas Valve 2 TP3 TP2 Gas Inlet 1 1 1 = Start Gas 2 = Main Gas Regulator NOTE: Orifice plate fitted into union between valve and burner where required. TP1 T Automatic Gas Valve & Regulator TP1 = Inlet Pressure TP2 = Pressure between Main Gas Valves TP3 = Valve Outlet Pressure Burner Pressure TP on Burner 2 TP3 TP2 T T Automatic NOTE: Orifice plate Gas Valve fitted into union between valve and burner for models 40/50, and burner flange for models 60 and over. SECTION 10: COMMISSIONING Figure 17: Dungs Gas Valve 10.4 Gas Valves Dungs Combination Gas Valve All model 015 - 030 gas-fired burners operate as direct main flame ignition and have no separate start gas train. All other models operate with a first stage start gas flame supplied from a start gas train containing a start gas pressure regulator and two safety shut-off valves, for all gas types. The main gas is released at the second stage, and the combination main gas valve block contains a main burner pressure regulator and two safety shutoff valves, for all gas types. See Page 37, Figure 17. For high/low or modulating burners, the Dungs gas valve has extra features because it is an air/gas ratio control valve. Please refer to the manufacturer’s instructions for setting the controls. 10.4.1 Start Gas Valves Where fitted, the start gas valve train is fitted with a pressure regulator and two start gas safety shut off valves. The start gas regulator is used to adjust the burner firing rate during the start gas phase of these models. 10.4.2 Main Gas Valves See Page 37, Figure 17 for the position of the burner pressure regulator. This must be used to set the burner pressure indicated in the data tables in Section 4. For high/low or modulating burners, the Dungs gas valve has extra features because it is an air/gas ratio control valve. Please refer to the manufacturer’s instructions for setting the controls. 10.4.3 Throughput Adjuster These valves have a throughput adjuster fitted to the second main gas valve. See Page 37, Figure 17. This will be factory set at fully open on new appliances and need no further adjustment. When replacing a gas valve, ensure that this device is set in the fully open position by releasing the locking screw and turning the "V MAX" fully counterclockwise towards the "+" and then retightening the locking screw. 10.4.4 Rate of Opening The slow opening adjustment can be seen on Page 37, Figure 17. This device is a hydraulic damper which slows down the rate of opening of the second main gas valve to give a smooth main gas ignition. This is preset at the factory at the slowest setting and will need no further adjustment. If a new valve is fitted, then remove the plastic screw on top and with a small screwdriver turn the "V Start" screw fully clockwise towards the "-" and refit the plastic cover. 10.5 Combustion Testing (all models) Combustion quality must be tested to prove correct heater operation. Incorrect results will indicate faults with the installation or appliance. Combustion testing must be carried out with all covers in place. The flue gas is sampled in the flue, within 1 meter of the heater. The values of CO2 should be between 9.5% and 10.0% for natural gas and 11% for LPG, depending upon the model. The CO will be up to 80 ppm (0.008%) dry, air free, depending upon the model. Temperature rise of the flue gases above ambient should be approximately 160°C to 180°C. Seal the test hole in the flue after testing. To alter combustion performance, open/close the combustion air damper to reduce or increase these values. Once adjusted to the optimum combustion setting, lock the air damper into position. Repeat the steps in Section 10.2.6. 37 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 10.5.1 Pressure Switch WARNING Electrical Shock Hazard Use extreme caution while commissioning. Failure to follow these instructions can result in death or electrical shock. Setting of the pressure switch must only be carried out as part of a complete commission which includes combustion testing. Remove the cover of the pressure switch. With the burner firing, turn the pressure switch dial to the setting indicated for that model and burner. See Page 8, Section 4.5 through Page 9, Section 4.6. 10.5.2 Complete the Commissioning Ensure that all covers are fitted correctly and all test points are properly sealed. 10.6 Commissioning the Burner (Oil Heaters) Check all valves between the fuel tank and the heater are open, including the fire valve. Ensure that oil is available at the heater inlet and that the air has been vented from the fuel pipe installation. Vent the air by opening the bleed screw on top of the fuel filter. On pressurised systems, check that the installation is running at the correct pressure. B.M. oil lifters will need priming. 10.6.1 Ensure that the burner head and air damper settings are adjusted for the correct burner and that the correct atomising nozzle is fitted. See Page 10, Section 4.7 and the burner reference number on the data plate. 10.6.2 Preparation for Burner Pressure Test Attach a pressure gauge 0-15 BAR (0 - 200 psi) to the burner pump pressure test port. (See manufacturer’s information). A test manifold gives you the facility for the connection of the pressure gauge and the venting of the pump. 10.7 Control - Oil-Fired Heaters For High/Low oil burners, follow the general sequence as described below and also have extra functional stages related to air damper positions. Refer to the burner manufacturer’s instructions for further detail. 10.7.1 Description of Oil Fired Heater Control The oil fired burners fitted to the heater are controlled by a fully automatic control and photoelectric flame monitor unit. This control ensures the safe start, ignition and stop sequence and also monitors the flame. If the flame should fail the control will go into "lockout". The button on ther front of the control will illuminate to indicate lockout. Press the button to reset the control to restart the burner firing cycle. Figure 18: Oil-Fired Heaters Control Box Sequence 10.5.3 High/Low and Modulating Burners After setting the minimum burner input and combustion, the following check must be made: Run the heater on low fire for a minimum of 15 minutes. Check the flue gas temperature. If the flue gas temperature falls below 125° C, increase the low fire gas setting until the temperature reaches 125° C, otherwise condensation may form. 38 SECTION 10: COMMISSIONING 10.7.2 Sequence of Operation The operating sequence is as follows: With the external controls on and calling for heat, the burner fan and electric ignition will switch on. After a combustion air purge of approximately twelve seconds, the oil solenoid valve will open and the burner will fire. After another five seconds, the electric ignition is turned off and the burner will go into its normal run position. The photo cell continuously monitors the safe presence of the flame. When the temperature control is satisfied, the control box will turn off all its outputs simultaneously and return to the rest position for the beginning of the next sequence. 10.7.3 Fault Display Messages On burner failure, the red LED is permanently illuminated for a period of approximately 10 seconds, followed by a brief “dark phase”, then one of the following flash-codes will indicate the cause of the fault. See Table 1 and Table 2. This indication will repeat as long as the lockout reset button is not reset. Table 1: Fault Display Flash-Code Key Message Pre-ignition Short Pulse l tv1 Safety Time Long Pulse l tv2 Delay Time to Valve V2 Short Pause . tv2 Running Long Pause _ Low Mains Voltage Flash-Code llll. ll. lll. l_ lll_ pump at the same time by loosening the pump vent port (pump must be running). If the burner goes into "lockout" before the pump has vented, wait one minute, then reset the control box and repeat 10.7.5 until all the air has been vented from the pump and the burner fires. NOTE: The burner plug and socket may be used to turn off the burner during commissioning. 10.7.6 Adjust Burner Oil Pressure Adjust the burner oil pressure to the value in the data table for the burner reference letter and burner manufacturer’s information for details of the burner oil pump. When completed, turn off burner and remove test gauge and refit plug. 10.7.7 Set Combustion Air The combustion air must be set. Measure the emissions in the flue at a point within one metre from the outlet of the heater and adjust for the highest carbon dioxide (CO2) levels obtainable, usually 10.5 - 11.0%, while making little or no smoke (smoke number 0-1). The test must be carried out with all covers fitted and after the heater has been running for 15 minutes. 10.7.8 Complete the Commissioning Test the burner for correct start and stop operation several times. Check that all safety devices operate correctly. Inspect the heater for any oil leaks and repair where necessary. 10.8 Turning Off the Heater (all models) Set the external controls to the “off” position and the main burner will stop. The fans will run until they are stopped automatically by the fan thermostat. Table 2: Error Diagnosis Error Message Flash-Code Lockout lllll Stray Light lllll Possible Fault Within lockout safety time, no flame established. Stray light during monitor phase, detector may be faulty. Flash-Code for Manual Lockout Manual/External Lockout lllll_lllll 10.7.4 Fault Conditions If at any stage during normal running the photo electric cell fails to detect the flame, the control will switch off and make an instant restart attempt. If the flame signal is still missing, “lockout” will occur. If the flame is not detected by the photo cell during a normal start, there will be no restart attempt and “lockout” will occur in approximately 17 seconds after the start. If a flame is detected during the first 12 seconds (purge), the solenoid valve will not open and the control will “lockout”. For the control sequence, see Page 38, Figure 18. Do not use Electrical Isolator for control of heater. The Electrical Isolator will switch off the fan. The heat exchanger could be damaged. The Warranty will not cover damage to the heat exchanger if operated improperly. 10.9 External Controls External controls may include a time switch, room thermostat and frost thermostat. Operate each control to ensure that they function correctly. Set the time switch (if fitted) and room thermostat to the user’s requirements. 10.10 Instruction to the User Explain the controls of the heater to the user, including how to turn it on and off, using the controls fitted on site. Give this manual to the user. Ensure that the user is shown and understands the importance of maintaining clearances to combustibles; the user instructions on Page 40, Section 11 through Page 41, Section 11.4; and all warnings defined in this manual. 10.7.5 Switching On Turn on the heater with the external controls. (Heat ON). If the "Lockout Reset" button is illuminated, press to reset. The combustion air fan and electric ignition should work immediately. Vent the burner oil 39 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 11: USER INSTRUCTIONS 11.1 User Instructions The COMBAT® Cabinet heaters are fully automatic and operate from the external controls fitted on site. The only user controls at the heater are the: Fan Run Button - See Page 40, Figure 20. Burner lockout reset button - See Page 41, Section 11.2.2. Limit thermostat reset button - See Page 40, Figure 20. WARNING Electrical Shock Hazard Disconnect electrical power before servicing. Failure to follow these instructions can result in death or electrical shock. to low fire. If the temperature rises to the second set point, the burner will turn off. The burner will come on again at either High or Low fire, depending on the thermostat set point. Set the two stage thermostat to the desired temperature. Modulating Operation The on-site control for modulating burners is a temperature controller that provides a varying output signal dependant upon the ambient temperature to the control. The burner firing rate will continuously vary between the maximum and minimum setting. If the temperature rises with the firing rate set to the minimum, the burner will shut down. Set the operating temperature according to the instructions provided with the control. 11.2 Common User Controls (all models) 11.2.1 Combination Fan/Limit Thermostat The Combination Fan/Limit Thermostat is located at the top right side of the heater. This control ensures the heater does not blow cold air in the normal heating cycle and protects the heat exchanger against overheating. Figure 20: Fan/Limit Thermostat 11.1.1 Heater Operation When the heater has been switched on by the remote controls installed on site, the main burner will automatically turn on. The burner control will control the safe ignition of the flame. When the heat exchanger is sufficiently heated, the fan thermostat turns on the main fan(s). All heaters require a constant gas and electricity supply, which must not be interrupted during the normal operation of this heater. NOTE: The fan will come on during burner firing for horizontally mounted and high-flow heaters and modulating burners. Figure 19: Heater Operating Sequence ON THERMOSTAT CALL FOR HEAT BURNER RUN FAN CLOSE DOWN ON ON 2-3 MINUTES RUN ON 11.1.2 Heater Operation (high/low or modulating) The heater will operate as described in Section 11.1.1 with these added features: High/Low Operation A second limit thermostat or a two-stage thermostat will be installed on site so that as the temperature reaches the first set point, the firing rate will reduce 40 If the air flow is reduced due to power failure, the limit thermostat will cause the burner to lockout. Red limit reset button (Press to reset) White fan button Pull out for normal operation. Press in for constant fan. The combination fan/limit thermostat is preset during commissioning. See Page 8, Section 4.4 and Page 34, Figure 13. NOTE: To reset, the heat exchanger must be cool. Description Combination Fan/Limit Thermostat Part Number K017A SECTION 11: USER INSTRUCTIONS Explosion Hazard If control locks out, do not make more than 3 attempts to restart the heater. Dangerous fuel mixtures can build up. The fault must be traced and repaired by a registered installer or service engineer. Failure to follow these instructions can result in death, injury or property damage. 11.2.2 Burner Lockout Reset Button The red warning light built into the burner control box will illuminate when the control has gone to lockout. This may be caused by flame failure. Wait one minute then press the reset button. 11.3 Lighting Instructions (all models) 11.3.1 To Turn On Heater 1. Ensure that the electrical and gas supplies to the heater are on. Check that the on-site controls are “ON”. NOTE: The thermostat setting must be above the ambient temperature for the heater to operate. 2. The automatic firing sequence will begin as described on Page 40, Figure 19. The heater will now operate automatically under the control of the on-site controls. Following long shut down periods, the control may go to lockout. See Page 41, Section 11.2.2. 11.4 Simple Fault Finding (all models) Some possible reasons for the heater not operating are: 1. Gas supply not turned ON. 2. Electricity supply not turned ON. 3. The time and/or temperature controls are not ON. 4. The Limit Thermostat may have operated. This may be caused by an interruption of the electrical supply or failure of the distribution fan. 5. The burner supply plug has been disconnected. If the Limit Thermostat persistently operates, there is a fault which must be investigated by a contractor qualified in the installation and service of gas or oilfired heating equipment. NOTE: If the main fan runs continuously, the white button (Figure 20) may have been pressed in - make sure it is pulled out. Alternatively, if a remote fan switch is fitted it may be in the ON position. 11.4.1 Simple Fault Finding (burner faults) If the burner fails to ignite for any reason, it will go to lockout. This will be indicated by the red light on the heater or at the remote indicator (if fitted). 1. Press in and release the lockout reset button on the burner or, if fitted, the remote reset. Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be corrected. 11.4.2 Simple Fault Finding (oil fired heaters) Make sure the appliance fuel valve is open and there is oil in the tank. If the fuel tank or lines have run dry, the fuel system will need to be vented. For venting oil-fired heaters, See Page 38, Section 10.6 through Section 10.7.5. 11.3.2 To Turn the Heater Off Set the installed remote controls to the “OFF” position or turn down the remote thermostat below the ambient temperature. The burner will turn off immediately. The fan will continue to run for a few minutes. To restart, turn the remote control to “ON". If the heater will remain off for a long period of time, when the main fan(s) have stopped, turn off the fuel supply valve and main electrical isolator. To restart open the fuel supply valve and follow the instructions in Section 11.3.1. 41 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. DO NOT try to light any appliance. 3. DO NOT use electrical switches. 4. DO NOT use any telephone in your building. 5. Leave the building. 6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions. 7. If you cannot reach your gas supplier, call the Fire Department. WARNING Fire Hazard Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance. Some objects will catch fire or explode when placed close to heater. Failure to follow these instructions can result in death, injury or property damage. 42 SECTION 12: SERVICING SECTION 12: SERVICING 12.1 Servicing Instructions After commissioning, the heater will require maintenance to be carried out annually. If the heater is used in a dirty or dusty area, more frequent maintenance may be necessary. Installation, Service and Annual Inspection of the heater must be done by a contractor qualified in the installation and service of gas or oil-fired heating equipment. 12.3 Fan/Motor Assembly Maintenance (all models) The main fan bearings are permanently sealed and do not need lubrication. Before cleaning, turn off fuel and electrical supply. Remove the heater side panels and use a small brush or duster to clean the fan blades from each side. Replace panels when done. Figure 21: Belt Tension 8 mm to 10 mm WARNING Motor Pulley Cut Hazard Turn off fuel and electrical supply before maintenance. Fan can start automatically at any time. Failure to follow these instructions can result in severe injury or product damage. NOTE 1: After any maintenance or repair work, always test fire the heater in accordance with the commissioning instructions on Page 33, Section 10 through Page 39, Section 10.10 to ensure all safety systems are in working order before leaving the heater to operate. Minor faults may be traced by using the troubleshooting charts on Page 45, Section 14 through Page 50, Section 14.7. NOTE 2: Check all fuel pipes and pipe joints to ensure there are no cracks or gas leaks. Any cracks in the pipes or pipe joints must be repaired. NOTE 3: Inspect all suspended components and hardware. Insure that they are in good condition, properly tightened, and corrosion free. 12.2 Burner Maintenance 1. See the manufacturer’s information for specific instructions. 2. Clean the fan (and fuel filters, when fitted). Inspect all components, including the flame monitoring and ignition system, and correct operation of fuel control valves. 3. For oil-fired burners it is recommended that the atomising oil nozzle be replaced during the annual service. Fan Pulley Check the condition and tension of the drive belts. The condition is best inspected with the belts removed. Check for chaffing or lateral cracks. Replace belts as a matched pair as necessary. Do not over-tighten belts, as this may cause bearing damage. 12.4 Heat Exchanger Maintenance Ensure that the front collector box is clean and that the turbulators fitted to the tubes are in good condition. Also inspect the joint between the heat exchanger and the flue to ensure that it is still sealed. 1. If maintenance is needed, remove the burner. See Page 51, Section 15.1. 2. Remove the upper front panel. 3. Remove the front cover of the heat exchanger. 4. Remove and inspect the turbulators. 5. Clean out any deposits from flue ways and the combustion chamber, using a vacuum cleaner and brush. Inspect the combustion chamber and heat exchanger for damage or corrosion. 6. Any damage must be referred to Roberts-Gordon. 7. Replace components in reverse order to above - replacing gasket material and any damaged turbulators. 8. Inspect and repair any damage to the seal between the flue and the flue spigot. 12.5 Thermal Insulation While the upper panels are removed for heat exchanger servicing, the thermal insulation fitted to all the upper panels must be inspected. Insulation should be sound, with the foil face in good condition. If any thermal insulation is in poor condition, then it must be replaced with new insulation material and suitably sealed at the edges with adhesive foil tape. 43 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 13: CONVERSION BETWEEN FUELS 13.1 General All COMBAT® Cabinet heaters may be operated on fuel oil, natural gas or propane gas, depending on which burner type has been fitted. Any conversion between fuels must be done by a contractor qualified in the installation and service of gas or oilfired heating equipment. Conversion must be carried out in accordance with the information provided to maintain compliance with the CE product certification. 13.2 Burner Conversion Burners designed to operate on class D (35 sec) fuel oil (Gas Oil) may be converted to operate on kerosine (28 sec). This may shorten the life expectancy of the fuel pump and fuel train components. Burners designed to burn natural gas may be converted to burn LPG propane gas or vice versa. For details of the changes necessary, please contact Roberts-Gordon with the heater serial number and burner type or consult the burner manufacturer’s information. Heaters designed to burn fuel oil may only be converted to burn gas by replacing the complete burner. Heaters designed to burn gas may only be converted to burn fuel oil by replacing the complete burner. 44 SECTION 14: TROUBLESHOOTING SECTION 14: TROUBLESHOOTING 14.1 General WARNING Explosion Hazard Installation must be done by a registered installer/ contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier. Failure to follow these instructions can result in death, injury or property damage. START Assuming fuel & electrical supplies are ON Does the burner fire? No Is the 'lockout' button on the No burner alight? Check if the control fuse in Yes the heater has blown. Yes No Test burner as in 14.2 (oil-fired), 14.3 (gas-fired). Check external controls are ON and the fuse in the burner is sound. Repair or Replace. Yes Does the main fan run? No Press in the white button on No fan/limit thermostat. Use 14.6 or 14.7 to test fan. Yes See Figure 13 to check thermostat settings. No Replace fan/limit thermostat. Did burner 'lockout' ? No Check main fan for blockage or belt tension and correct rotation. Yes Does the burner stop after Yes running for several minutes with controls still ON ? Yes No Test burner as in 14.2 (oil-fired), 14.3 (gas-fired). Check operation and setting of fan/limit thermostat. Repair or replace as necessary. No Heater Operating TROUBLESHOOT ENDS. No If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0)121 506 7709 www.rg-inc.com For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts. Conduct Commissioning procedure as shown on Page 33, Section 10. 45 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 14.2 Troubleshooting for Oil Burners (see manufacture’s instructions) WARNING Electrical Shock Hazard Do not touch ignition components. Voltage from ignition components is high. Failure to follow these instructions can result in death or electrical shock. START Assuming fuel & electrical supplies are ON Does the burner fire? No Check if the control fuse in No the heater has blown. Yes Check supply to burner motor. Yes No Check control box. No Repair or replace. Yes Does the burner control box 'lockout' before 15 seconds? Yes Disconnect photo cell and try again. No Control box faulty. Repair or replace. Yes Use Section 14.4 to trace fault. No Does the burner control box 'lockout' after 15 seconds? Yes Did the burner fire? Check ignition electrodes are No set as in the manufacturer's instructions, the fuel supply and nozzle. Yes No Use Section 14.4 to trace fault. Check oil solenoid valve. No Heater Operating TROUBLESHOOT ENDS. No If problems persist, contact ROBERTS GORDON® at Tel: +44 (0)121 506 7709 www.rg-inc.com For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts. Conduct Commissioning procedure as shown on Page 33, Section 10. 46 SECTION 14: TROUBLESHOOTING 14.3 Troubleshooting for Gas Burners (see manufacturer’s instructions) WARNING Electrical Shock Hazard Do not touch ignition components. Voltage from ignition components is high. Failure to follow these instructions can result in death or electrical shock. START Assuming fuel & electrical supplies are ON. Does the burner fan run? No Is the pressure switch at rest? (no contact open) No See Section 10.5.1 for setting. Yes Fault lies elsewhere. Yes Does the burner control box 'lockout' before 10 seconds? Yes Use Section 14.4 to check the flame monitoring system. Yes Check settings pressure switches. No Check ignition circuit, fuel supply and gas solenoid valves. Yes Use Section 14.4 to check the flame monitoring system. No Check main gas valves and wiring. No If problems persist, contact ROBERTS GORDON® at Tel: +44 (0)121 506 7709 www.rg-inc.com No Does the burner control box 'lockout' after 10 seconds? No Does the burner fire? No Check combustion air fan is clean. Check combustion chamber is clean and sound. Check flue is clean and sound. Check joint between flue spigot and flue is sound. Yes Does 'lockout' occur? No Does main gas fire? Yes Heater Operating TROUBLESHOOT ENDS. 47 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 14.4 Troubleshooting for Flame Supervision System The flame supervision system is different for gas-fired and oil-fired heaters but may be tested in a similar way. Gas-fired heaters use a rectification flame probe to monitor the flame. Oil-fired heaters use a photo sensitive cell to monitor the flame. To connect a suitable meter into the circuit to monitor the flame signal current, disconnect one of the wires to the monitor (there is only one for gas-fired). Connect a suitable DC ammeter between the terminal just disconnected and the wire taken from it. Should the meter read backwards, then reverse its connections. Readings should be approximately as follows(For further details see burner manufacturer’s instructions): Oil-Fired Maximum flame Minimum flame current with no current with flame flame 12 μ Amp 25 μ Amp Gas-Fired Maximum flame Minimum flame current with no current with flame flame 0.5 μ Amp 1.0 μ Amp START Connect a DC ammeter in series with the flame monitor. Turn on all controls and ensure supply to burner Is there a current flowing in excess of the max. value for NO flame? Yes No Does 'lockout' occur when Yes a flame is present? OIL-FIRED Is there a stray light entering the burner or is there a flame? GAS-FIRED Inspect and test the flame probe and wiring for a short circuit to earth. OIL-FIRED Clean or replace photo electric cell as necessary. GAS-FIRED Replace flame probe. Check for it's correct position. Check wiring to flame probe. Check burner earth connection. No 'Lockout' still occurs? Yes Control box faulty. Replace with correct type. No If problems persist, contact ROBERTS GORDON® at Tel: +44 (0)121 506 7709 www.rg-inc.com No Heater Operating TROUBLESHOOT ENDS. 48 Repair or replace. 14.5 Troubleshooting for Solenoid Valves Circuit START Is there pressure on the outlet of the valve when the Yes valve should be closed? Is there an electrical supply Yes to the valve terminals? Fault lies elsewhere. Investigate and correct. No Valve faulty. Replace with correct type. No Does valve open at the correct time? No Is there an electrical supply Yes to the valve terminals? Fault lies elsewhere. Investigate and correct. No Valve faulty. Replace with correct type. Yes Valve Operating TROUBLESHOOT ENDS. No If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0)121 506 7709 www.rg-inc.com 14.6 Troubleshooting for Main Fan Circuit (1 Ø) START Main fan will not operate following warm up period of heat exchanger. Check for 230 V at terminals 1 to N. No Press in white button of fan/limit thermostat and retest. No No Fault lies elsewhere. Yes Yes Check the setting of the fan thermostat as in Figure 13. Re check supply to terminals L1 to N. Yes Check calibration of the fan thermostat. The dial should indicate the approximate temperature of the sampled air. No Fan thermostat faulty. Replace and reset. Yes Check and test wiring to motor. Does the motor run now? No Motor faulty. Replace complete fan unit. Yes Thermal overload in motor is faulty. Replace complete fan unit. No If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0)121 506 7709 www.rg-inc.com Yes Motor stops after running some time. No Motor running. TROUBLESHOOT ENDS. For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts. Conduct Commissioning procedure as shown on Page 33, Section 10. 14.7 Troubleshooting for Main Fan (3 Ø) START Main fan will not operate following warm up period of heat exchanger. Check for 400 V three phase No supply at main terminals. Fault lies elsewhere. Yes Check for 230 V at terminals No 1 to N Press in white button of fan/limit thermostat and retest. No Fault lies elsewhere. Yes Check calibration of the fan thermostat. The dial should indicate the approximate temperature of the sampled air. Yes Check the setting of the fan thermostat as in Section 5.1. No Fan thermostat faulty. Replace and reset. Yes Check for 230 V at coil terminals of fan contactor. No Does fan run now? No Reset thermal overload and check setting. See page 28, Section 10.1.6. Check for 400 V three phase at input and output of No contactor. Contactor or overload faulty. Replace as necessary. Yes Check and test wiring to motor. Motor faulty. Replace complete fan unit. Yes Motor stops after running some time. Yes Thermal overload in motor is faulty. Replace complete fan unit. (direct drive fans only) No If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0)121 506 7709 www.rg-inc.com No Motor running. TROUBLESHOOT ENDS. For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts. Conduct Commissioning procedure as on Page 33, Section 10. SECTION 15: REMOVAL AND REPLACEMENT PARTS SECTION 15: REMOVAL AND REPLACEMENT PARTS See warnings and notes on Page 43, Section 12 before removing or replacing parts. a new fuse into the spring clips. To replace the holder, remove the fuse, pull off the two tag connectors from either end, and then unscrew the central screw. Reverse these instructions to refit. 15.1 Burner Components To remove the burner from the heater: 1. Unplug the burner electrical supply from the heater. 2. Isolate the fuel supply at the inlet manual valve and disconnect the inlet fuel pipe. 3. Unscrew the nuts holding the burner mounting flange to the heater. 4. Remove the burner from the heater, retaining the gasket for reuse. For removal of burner components, follow the manufacturer’s instructions. To refit the burner, reverse the instructions above. Fit the gasket between the burner mounting flange and the heater. Use a new gasket if necessary. 15.4 Combination Fan/Limit Thermostat To gain access to the thermostat: 1. Loosen the cover retaining screw (on top) and remove cover. 2. Disconnect the electrical connections by pushing in with a small screwdriver and pulling out the wiring. See Page 52, Figure 22. 3. Unscrew the conduit bush and the two screws and withdraw the unit from the cabinet. 4. Reverse these instructions to refit. See Page 34, Figure 13 to set the new thermostat. 15.2 Direct On-Line Main Fan Starter and Thermal Overload Unit (3 Ø) This assembly comprises two parts, the contactor and the overloads, which may be changed seperately. 15.2.1 The Contactor To remove the contactor: 1. Remove the overloads as on Page 51, Section 15.2.2. 2. Remove the line connections to the top of the contactor (noting the colour code) and the two coil connections at the top rear of the contactor. 3. Unscrew the fixing screws to remove the contactor from the panel. 4. Reverse these instructions to refit. Check rotation of the fan after working on the contactor. 15.2.2 The Overloads (models 060 to 100) To remove the overloads: 1. Unscrew the motor connecting wires from their terminals at the bottom of the assembly. Note the colour code. 2. Disconnect the overload circuit connections near the overload reset button. 3. Disconnect the overload fixing and connecting screws from the bottom of the contactor. 4. Ensure that any replacement overload is of the correct rating and that it is reset correctly. See Page 33, Section 10.1.6. 15.3 Control Circuit Fuse (10 or 5 A, 1-1/4" long sand filled) The control fuse is removed by grasping the centre and pulling it out of the spring clips. To replace, push 15.5 Main Fan Motor (3 Ø Belt Drive) 1. Disconnect electrical connections at contactor and overloads. See Page 51, Section 15.2. 2. For Star/Delta starters, there are six wires between the motor and the starter. 3. Remove the left lower side panel to access the motor. 4. Unscrew the bolts securing the motor to the mounting bracket. Lift the motor out. 5. Reverse these instructions to refit, tensioning the belts as on Page 43, Figure 21 and ensuring the pulleys are aligned. 6. For Star/Delta starters, pay specific attention to the six motor connections. 15.6 Main Fan Units Depending on the model of the heater, the main fan unit will be direct drive (with integral motor) or belt drive. Models 060-100 are belt drive, double fan units. All the fans are secured to the base of the heater by four bolts per fan case, and to the fan tray by bolts through the outlet flange. To gain access to the fans: 1. Remove the lower side panels of the heater. For models 060-100 and High Flow models, remove the upper side panels of the same side and the vertical centre bar to allow the fans to slide out of the cabinet. 2. Disconnect the electrical connections. On direct drive units, these will be at the terminal block for single phase and at the contactor for three phase. 3. Remove the screws. The fan will pull out of the heater through the side. 4. Reverse these instructions to refit, tensioning the belts as on Page 43, Figure 21. 51 COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 5. Check the correct rotation of the fan as on Page 33, Section 10.1.5. NOTE: The direct drive fan unit motor can only be replaced as a complete fan/motor assembly. Figure 22: Combination Fan/Limit Thermostat WARNING Fire Hazard Break-off link must be removed from replacement thermostat. Heat exchanger damage may result. Failure to follow these instructions can result in death, injury, property damage or product damage. Dial Set Point 3 Limit Temp. Set Point 2 Fan On Push Screwdriver in and hold to release Set Point 1 Fan Off Push in Lock Wire to Controlled Equipment Fan Terminals Limit Stat Manual Fan Switch (White) Pull out for normal operation. Push in for continuous fan. Manual Reset Button (Red) Limit Terminals ® ROBERTS GORDON BREAK-OFF LINK thermostats do REMOVED not have a MUST BE break-off link. Remove break-off link if thermostat was not provided by Roberts-Gordon. 52 SECTION 16: PARTS LIST SECTION 16: PARTS LIST The following items are recommended as spares which may be required during routine service and replacement of the air heater. There is also a list of parts in the burner manufacturer’s manual which relates to the parts required for the packaged burner fitted to the heater. 015 020 030 040 050 060 070 080 0100 16.1 Spare Parts List A 025 DDC 1220 Direct Drive Fan 1 1 1 - - - - - - A 029 DDC 1500 Direct Drive Fan - - - 1 1 - - - - A 038 BDC 1500 Belt Drive Fan - - - - - 1 1 1 1 A 136 A49 Vee Belt - - - - - 2 2 2 2 K 017 Combination Fan/Limit Thermostat 1 1 1 1 1 1 1 1 1 D 004A Motor Contactor - - - - - 1 1 1 1 D 020A Motor Overload 4.5/7.5 A - - - - - 1 1 1 - D 024A Motor Overload 6-10 A - - - - - - - - 1 Part No. Description 53 Attach this information to the wall near the ROBERTS GORDON® heater ® Read the Installation, Commissioning, Operation and Service Manual thoroughly before installation, operation or service. WARNING OPERATING INSTRUCTIONS 1. STOP! Read all safety instructions on this information sheet. 2. Open the manual fuel valve in the heater supply line. 3. Turn on electric power to the heater. 4. Set the thermostat to desired setting (above ambient temperature). The automatic starting sequence begins. NOTE: Following long shutdown periods, the burner control may go to ‘LOCKOUT’ during the start sequence. Push the reset button to recommence firing. Contact service department if ‘LOCKOUT’ continues (see manual for details). TO TURN OFF THE HEATER 1. Turn the thermostat/time switch to ‘OFF’. The burner will turn off immediately, but fans will continue to cool theheat exchanger until the fan thermostat switches off. IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY, FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER 1. Set the thermostat to ‘OFF’ or the lowest setting. 2. Turn off electric power to the heater. 3. Turn off the manual fuel valve in the heater supply line. 4. Call your registered installer/contractor qualified in the installation and service of gas or oil-fired heating equipment. Fire Hazard Some objects can catch fire or explode when placed close to heater. Keep all flammable objects, liquids and vapours the required clearances to combustibles away from heater. Failure to follow these instructions can result in death, injury or property damage. Clearances to Combustibles Installation Clearances .6 m .6 m .6 m 4m .6 m .6 m Roberts-Gordon Europe Limited Unit A, Kings Hill Business Park Darlaston Road, Wednesbury West Midlands WS10 7SH UK Telephone: +44(0)121 506 7700 Fax: +44(0)121 506 7701 Service Telephone: +44(0)121 506 7709 Service Fax: +44(0)121 506 7702 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com Roberts-Gordon, LLC 1250 William Street P.O. Box 44 Buffalo, NY 14240-0044 USA Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450 Installation Code and Annual Inspections: All installations and service of ROBERTS GORDON® equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts-Gordon and conform to all requirements set forth in the ROBERTS GORDON® manuals and all applicable governmental authorities pertaining to the installation, service and operation of the equipment. To help facilitate optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON® equipment and perform service where necessary, using only replacement parts sold and supplied by Roberts-Gordon. For installations at elevations above 2000' (610 m), the appliance shall be derated 4% for each 1000' (305 m) of elevation above sea level. Further Information: Applications, engineering and detailed guidance on systems design, installation and equipment performance is available through ROBERTS GORDON® representatives. Please contact us for any further information you may require, including the Installation, Commissioning, Operation and Service Manual. This product is not for residential use. © 2007 Roberts-Gordon, LLC www.rg-inc.com Printed in U.S.A. P/N 91040095
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