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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WARNING

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 suppliers

instructions.

7. If you cannot reach your gas

supplier, call the Fire Department.

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.

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

WARNING

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.

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.

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.

Quality in Any Language™

Combat®

Installation, Commissioning,

Operation & Service Manual

OIL-FIRED:

Model POP-ECA

015 to 0100

GAS-FIRED:

Model PGP-ECA

015 to 0100

P/N X523 Rev G 10/08

Cabinet Heaters

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 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

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

SECTION 1: HEATER SAFETY

Your Safety Is Important to Us!

This symbol is used throughout the

manual to notify you of possible fire,

electrical or burn hazards. Please pay

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

qualified in the installation and service of gas/oil-

fired heating equipment.

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

clearances to combustibles. Affix the tag on a wall

near the heater.

2.2 Corrosive Chemicals

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 com-

pounds are frequently used in refrigerants, cleaning

agents, solvents, etc. If these compounds enter the air

supply of the burner, the lifespan of the heater compo-

nents 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 commer-

cial 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.

CAUTION

Do not use heater in an area containing corrosive

chemicals.

Corrosive chemicals will damage the burner and

heat exchanger parts.

Failure to follow these instructions can result in

property damage.

SECTION 3: CRITICAL CONSIDERATIONS

3.1 Basic Information

Cabinet heaters are supplied with burners suitable

for on/off operation as standard. As an option, oil-

fired 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 installa-

tion.

• 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 horizon-

tally, the heater will normally lie on its left side

when viewed from the burner. The same clear-

ances and comments on panels must be used,

except for the side the heater lies on.

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.

3.7 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).

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 1: Installation Clearances and Clearances to Combustibles

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.

*.6 m *.6 m

.6 m

4 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.

SECTION 4: SPECIFICATIONS

4.1 PGP & POP Internal Heaters

Dimension Data - PGP & POP Internal Heaters

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.

70 38

38 38

108

Front View

(all models) Side View

(Models 015 - 050)

Rear View

(all models)

Side View

(Models 060 - 0100)

Model 015/020 030 040 050 060/070/080 0100

AWidth mm

(in)

724

857

1016

BDepth, Cabinet Only mm

(in)

857

1016

1676

1994

CHeight, Cabinet Only mm

(in) 1740

69 1740

69 1930

76 1930

DDepth, Overall mm

(in)

1267

1337

1496

2156

2496

EHeight, Including Heads mm

(in)

1988

2058

2235

FLeft/Right Air Inlet Spigot - Depth mm

(in) 781

31 781

31 940

37 1600

63 1918

GLeft/Right Air Inlet Spigot - Height mm

(in)

457

560

559

HRear Air Inlet Spigot - Depth mm

(in)

648

781

31 NA NA

JRear Air Inlet Spigot - Height mm

(in) 361

14 361

14 446

18 446

18 NA NA

Flue Diameter* mm

(in)

178

229

Weight kg 200 200 245 270 440 530

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

4.2 PGP & POP External Heaters

Dimension Data - PGP & POP External Heaters

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.

38 38

275

B E

38 38

108

Front View Side View Rear View

Model 015/020/030 040 050 060/070/080 0100

AWidth mm

(in) 724

29 857

34 857

34 1016

40 1016

BDepth, Cabinet Only mm

(in)

857

1016

1676

1994

CHeight, Cabinet Only mm

(in)

1740

1930

DDepth Overall mm

(in) 1396

55 1498

59 1657

65 2483

98 2800

110

EExternal Heater Housing mm

(in)

373

474

639

FWidth Overall mm

(in)

840

973

1132

GAir Outlet Spigot - Depth mm

(in) 476

19 476

19 610

24 1238

49 1524

HAir Outlet Spigot - Width mm

(in)

648

781

940

JFlue Diameter mm

(in)

178

229

KRear Return/Fresh Air Inlet - Width mm

(in) 648

26 781

31 781

31 NA NA

LRear Return/Fresh Air Inlet - Height mm

(in)

178

229

MLeft/Right Return Fresh Air Inlet - Height mm

(in)

457

560

NLeft/Right Return Fresh Air Inlet - Width mm

(in) 781

31 781

31 940

37 1600

63 1918

PRear of Heater to Air Outlet Spigot* mm

(in)

401

426

SECTION 4: SPECIFICATIONS

4.3 Air Outlet and Flue Arrangements

4.3.1 Vertical and Horizontal Heaters - Free Blowing (top view)

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)

Outlet Spigot Dimensions

165

015/020

165

030

203

040

229

050

184

060/070/080

284

0100

38 38

100

343

015/020/030

38 38

100

343

040

38 38

100

368

050

100

400

38 38

060/070/080

432

100

38 38

0100

Model 015/020/030 040 050 060/070/080 0100

KSpigot width mm

(in) 648

26 781

31 781

31 940

37 940

LSpigot Depth mm

(in)

476

610

1238

1524

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

4.4 General Technical Data Table (all models)

Appliance Category II 2H/L 3B/P

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")

NOTE: For adjustment of head setting, see Ecoflam Instructions

Model 015 020 030 040 050 060 070 080 0100

Electrical Supply* 230 V / 50 Hz / 1 Ø 400 V / 50 Hz / 3 Ø

Main Fan Motor Type Direct Drive Belt Drive

Motor Size (kW) 0.75 2.2 1.5 2.2 4.0

Motor Pulley (PCD) NA 2 A x

80 mm 2 A x 95 mm 2 A x

106 mm

Fan Pulley (PCD) NA 2 A x

180 mm 2 A x

180 mm

Start Current (Amps) 24 24 28 21 21 10.2 30 30 35

Run Current (Amps) 5.3 5.3 6.3 6.2 6.2 3.5 5.1 5.1 9.6

Airflow (m3/h) 3398 3398 5097 6796 8495 11044 12443 12443 17330

Free Blowing (ft3/min) 2000 2000 3000 4000 5000 6500 7500 7500 10200

Model 015 020 030 040 050 060 070 080 0100

Gross Heat Input (kW)

(Btu/h) x (1000) 55.5

189.4 73.3

250.1 93.2

318.0 129.9

443.2 162.0

552.7 208.0

709.7 242.0

825.7 275.2

939.0 348.5

1189.1

Net Heat Input (kW)

(Btu/h) x (1000)

50.0

170.6

66.0

225.2

84.0

286.6

117.0

399.2

146.0

498.2

187.4

639.4

218.0

743.8

248.0

846.2

314.0

1071.4

Heat Output (kW)

(Btu/h) x (1000)

47.4

161.7

61.2

208.8

78.4

267.5

110.2

376.0

134.5

458.9

177.7

606.3

205.3

700.5

230.4

786.1

293.4

1001.1

Pressure Switch Setting (mbar) 1.5 4.5 4.0 6.5 5.0 6.5 7.5 7.0

Flue Static Pressure (mbar) -0.05 -0.05 -0.09 -0.30 -0.05 -0.25 -0.17 0.10 0.45

Gas Connection (in) 3/4" 1 1/4"

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 mbar 4.0 2.7 4.2 4.8 7.7 5.2 7.1 9.5 10.0

Start Gas Pressure mbar NA NA NA 1.8 2.8 0.9 1.1 1.7 3.4

Gas Rate (m3/h)

(ft3/h)

5.3

187 7.0

247 8.9

314 12.4

438 15.4

546 19.8

701 23.1

816 26.2

928 33.2

1175

Start Gas Orifice (mm dia) 5.0 6.0 7.0 7.0 7.0

Burner Type AZUR 60 BLU 120 BLU 120 BLU 170 BLU 250R BLU 250 BLU 250 BLU 250S BLU 350

Burner Head SSSSSSSSS

Burner Head Setting (mm) 0 10 11 15 14 24 24 24 21

Air Setting 2.6 4.2 6 2.2 3.5 2.9 3.6 1.4 1.6

Valve Type Main Gas MBDLE

405

MBDLE

407

MBDLE

410

MBDLE

412

Valve Type Start Gas NA 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 mbar 4.2 3.3 4.6 4.8 7.5 5.8 7.8 12.0 7.6

Start Gas Pressure mbar NA NA NA 1.6 2.5 0.8 1.0 1.5 3.1

Gas Rate (m3/h)

(kg/h)

2.1

3.9 2.8

5.1 3.5

6.5 4.9

9.1 6.1

11.3 7.8

14.5 9.1

16.9 10.4

19.2 13.1

24.3

Start Gas Orifice (mm dia) 5.0 6.0 7.0 7.0 7.0

Main Gas Orifice (mm dia) 8.5 10.0 10.0 14.5 14.5 14.5 14.5 14.5

Burner Type AZUR

60 AH BLU

120 AH BLU

170 AH BLU

250R AH BLU

250 AH BLU

250S AH BLU

350 AH

Burner Head S S S S S S S S LPG

Burner Head Setting (mm) 0 10 13 15 14 24 24 24 20

Air Setting 3.0 4.8 6.6 2.6 4.5 3.1 4.2 1.6 1.8

Valve Type Main Gas MBDLE

405

MBDLE

407

MBDLE

410

MBDLE

412

Valve Type Start Gas NA S.I.T. 0 832 051

SECTION 4: SPECIFICATIONS

4.6 Technical Data - Ecoflam Modulating Burners (all models - burner reference "H")

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.

Model 015 020 030 040 050 060 070 080 0100

Maximum Gross Heat Input (kW)

(Btu/h) x (1000)

55.5

189.4

73.3

250.1

93.2

318.0

129.9

443.2

162.0

552.7

208.0

709.7

242.0

825.7

275.2

939.0

348.5

1189.1

Maximum Net Heat Input (kW)

(Btu/h) x (1000) 50.0

170.6 66.0

225.2 84.0

286.6 117.0

399.2 146.0

498.2 187.4

639.4 218.0

743.8 248.0

846.2 314.0

1071.4

Minimum Gross Heat Input (kW)

(Btu/h) x (1000)

38.9

132.7

51.3

175.0

65.2

222.5

90.9

310.2

113.4

386.9

145.6

496.8

169.4

578.0

192.6

657.2

244.0

832.5

Minimum Net Heat Input (kW)

(Btu/h) x (1000)

35.0

119.4

46.2

157.6

58.8

200.6

81.9

279.5

102.2

348.7

131.2

447.7

152.6

520.7

173.6

592.3

219.8

750.0

Maximum Heat Output (kW)

(Btu/h) x (1000) 47.4

161.7 61.2

208.8 78.4

267.5 110.2

376.0 134.5

458.9 177.7

606.3 205.3

700.5 230.4

694.0 293.4

1001.1

Minimum Heat Output (kW)

(Btu/h) x (1000)

113

147

188

263

321

124

423

144

491

161

549

205

699

Pressure Switch Setting (mbar) 1.5 1.0 1.5 2.0 2.5

Flue Static Pressure (mbar) -0.05 -0.05 -0.09 -0.30 -0.05 -0.25 -0.17 0.10 0.45

Gas Connection (in) 3/4" 1 1/4"

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 (mbar) 4.9 2.4 3.3 4.1 6.7 5.2 6.7 8.0 8.6

Min. Burner Gas Pressure (mbar) 3.2 2.8 2.4 2.3 3.7 2.5 3.4 4.3 5.4

Start Gas Pressure (mbar) NA NA NA 1.1 1.8 0.6 0.7 0.9 1.0

Maximum Gas Rate (m3/h)

(ft3/h)

5.3

187

7.0

247

8.9

314

12.4

438

15.4

544

19.8

699

23.1

816

26.2

925

33.2

1172

Minimum Gas Rate (m3/h)

(ft3/h)

3.8

134

5.0

177

6.3

222

8.8

311

11.0

388

14.2

501

16.5

583

18.7

660

23.7

837

Start Gas Orifice (mm dia) NA NA NA 7.0

Burner Type AZUR 60 BLU 120 BLU 120 BLU 170 BLU 250R BLU 250 BLU 250 BLU 250 BLU 350

Burner Head S S S S S S S S S

Burner Head Setting (mm) 0.0 8.0 10.0 15.0 14 T.O.

Low Flame Air Orange Cam ** 20° 13° 22° 18° 22° 25°

High Flame Air Red Cam ** 33° 40° 80° 30° 32° 30° 35° 55° 60°

Gas Valve Setting 0-1, 5 0-1 0-1, 4

Valve Type Main Gas MBDLE 407 MBDLE 412

Valve Type Start Gas NA 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 (mbar) 4.3 5.7 4.7 3.1 5.9 5.3 7.2 9.0 6.4

Min. Burner Gas Pressure (mbar) 2.3 2.9 1.4 1.6 2.0 2.3 2.5 3.2 2.0

Start Gas Pressure (mbar) NA NA NA 1.1 1.7 0.6 0.7 0.7 1.5

Maximum Gas Rate (m3/h)

(kg/h)

2.09

3.87 2.76

5.11 3.51

6.49 4.89

9.05 6.10

11.29 7.83

14.49 9.11

16.86 10.36

19.18 13.12

24.29

Minimum Gas Rate (m3/h)

(kg/h)

1.46

2.71 1.93

3.58 2.46

4.55 3.42

6.34 4.27

7.90 5.48

10.15 6.38

11.80 7.25

13.42 9.18

17.00

Start Gas Orifice (mm dia) NA NA NA 7.0

Main Gas Orifice (mm dia) 8.5 10.0 14.5 NA

Burner Type AZUR 60 BLU 120 BLU 120 BLU 170 BLU 250R BLU 250 BLU 250 BLU 250 BLU 350

Burner Head S S S S S S S S S

Burner Head Setting (mm) 0.0 8.0 10.0 15.0 14 T.O.

Low Flame Air Orange Cam ** 20° 13° 22° 18° 22° 25°

High Flame Air Red Cam ** 33° 40° 80° 30° 32° 30° 35° 55° 60°

Gas Valve Setting 0-1, 4 0, 3-0, 9 0-1, 1 0-1, 4 0-1, 5 0-0, 85

Valve Type Main Gas MBDLE 407 MBDLE 412

Valve Type Start Gas NA S.I.T. 0 832 051

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

4.7 Technical Data - Ecoflam Oil-Fired Burners (burner reference "G")

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.

Model 015 020 030 040 050 060 070 080 0100

Gross Heat Input (kW)

(Btu/h) x (1000)

55.5

189.4

73.3

250.1

93.2

318.0

129.9

443.2

162.0

552.7

208.0

709.7

242.0

825.7

275.2

939.0

348.5

1189.1

Heat Output (kW)

(Btu/h) x (1000) 47.4

161.8 61.2

208.9 78.4

267.4 110.2

375.9 134.5

458.8 177.7

606.5 205.3

700.3 230.4

786.2 293.4

1001.0

Burner Type Minor 8 Minor 12 Minor 20 Minor 30 Major 30

Oil Pump Connections (in) 3/8

Light Fuel Oil (Gas Oil) Data

Nozzle Size *US (gal/h) 1.00 1.50 1.75 2.50 3.50 4.00 5.00 5.00 7.00

Angle & Type 60S 60A

Make Danfoss Delavan

Head Setting (mm) 8 0 14 (full back) (fixed)

Air Setting (number) 4.2 8.5 5.5 3 4 3.7 4 6.2 1.8

Burner Fuel Pressure (Bar)

(lbf/in2)

12.1

175

10.3

150

12.4

180

11.7

170

10.0

145

11.0

160

10.0

145

13.0

188

11.0

160

Fuel Consumption (L/h)

*UK (gal/h) 5.17

1.14 6.82

1.50 8.68

1.91 12.09

2.66 15.08

3.32 19.36

4.26 22.53

4.96 25.62

5.63 32.44

7.14

Maximum Oil Pressure to

Pump Inlet

(Bar)

(lbf/in2)

.21

Kerosene Data

Nozzle Size *US (gal/h) 1.25 1.75 2.50 3.00 4.00 5.00 6.00 6.50 8.50

Angle & Type 60S 60B

Make Danfoss

Head Setting (mm) 8 0 14 (full back) (fixed)

Air Setting (number) 4 6.6 6 3 4 3.7 4.5 6 1.4

Burner Fuel Pressure (Bar)

(lbf/in2)

8.6

125

9.7

140

8.3

120

9.7

140

8.3

120

9.0

130

8.3

120

9.3

135

8.3

120

Fuel Consumption (L/h)

*UK (gal/h) 5.47

1.20 7.23

1.59 9.19

2.02 12.81

2.82 15.98

3.51 20.52

4.51 23.87

5.25 27.14

5.97 34.37

7.56

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

1 m

Minimum

Roof

Flues up to 200 mm dia. are

fitted with Bird Screens, over

200 mm with a Rain Cap.

Air

Distribution

Heads

Flue

Lead Roof Plate

Building Ventilation

Electric Supply

Gas Isolating Valve

Union

Connection

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 3: Typical Installation of a Oil-Fired Cabinet Heater

1 m

Minimum

Roof

Flues up to 200 mm dia. are

fitted with Bird Screens, over

200 mm with a Rain Cap.

Air

Distribution

Heads

Flue

Lead Roof Plate

Building Ventilation

Electric Supply

Fire Valve

Fuel FilterManual Isolating

Valve

Fusible

Link

Fuel

Tank

Gauge

FillerVent

Gate Valve

Plugged Drain Valve

SECTION 6: FLUE INSTALLATION

6.1 Flue Installation

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,

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.

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

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.

1 m

Minimum

Roof

Wall

*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.

*Less than

2.5 m

Nearby

Structure

*1 m

Minimum

Flues up to 200 mm dia. are fitted

with Bird Screens, over 200 mm

with a Rain Cap.

Use adequate

support to

prevent heater

from carrying

the weight of

the flue.

135°

Roof

Wall

Minimum Total

1m +

(0.5m for each 135° bend) +

(1m for each 0.33m of flue

running in the 135° direction)

1 m

Minimum

above roof

Use adequate

support to

prevent heater

from carrying

the weight of

the flue.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 6: Guy Wire

Figure 7: Socket Direction

Figure 8: Flue and Roof Detail

Figure 9: Flue and Heater Spigot Joint Detail

Over 2 m

use Guy Wires

Roof

Wall

Use adequate

support to

prevent heater

from carrying

the weight of

the flue.

Male spigot

facing down.

Screws,

four typical.

Roof

Flue

Terminal

Conversion Collar -

last joint below

the roof line.

Male spigot

facing up.

Clamp Ring

Metal Sleeve

Masterflash

Soaker Flashing

or Rain Collar.

Screws

Roof

Seal Rain Collar

joint with high

temperature

silicon

sealer

Secure Bolts

Stainless Steel

Roof Tidy Plate

Heat Sealed

Flash Band

Roof Plate

Clamp ring

Screws,

four typical.

Rain Collar

Heater

Spigot

Fire

Cement Heat

Resistant

Rope

Tidy

Plate

Screws

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.

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.

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 con-

nected 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 pro-

vided for operational adjustment in these ducts,

they shall be proved in the correct position dur-

ing the operation of the burner.

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).

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

SECTION 8: FUEL PIPING

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.

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.

IMPORTANT - The complete installation must be

purged and tested for gas soundness in accordance

with local and national codes.

Figure 10: Gas Connection

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.

Gas Isolating Valve

Drip Leg

Union

Connection

Medium or Heavy

Gauge Tubing

Gas Connector

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.

8.2.2 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.

8.2.3 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.

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.

8.2.5 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.

Figure 11: B. M. Oil Lifter

Technical Data

Maximum Lift............. 8 m

Maximum Capacity.... 20 L/h

Actual Capacity.......... 10 - 20 L/h

Dependant upon vertical lift and suction

line length.

Max 3m

Min 0.15m

Max 8m

Min 0.15m

Flow Output - L/h

Flow Output - UK gal/h

240 V

Oil Lifter

Air Vent

Filler Pipe

Storage Tank

50 mm

Total Suction Length in Feet

8mm (5/16”) O.D. Copper Tube

Lift in Feet

Lift in Metres

0 5 10 15 20 25

0 1 2 3 4 5 6 7 8

33’

65’

99’

132’

165’

Oil

Heater

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 12: Pressurised System Installation - Duplex System

Check

Valve

Check

Valve

Relief Valve

Pressure Gauge

Check

Valve

Stop

Valve

Stop

ValveStop

ValveBurner

No. 1

Pump

No. 2

Pump

Duplex Pump Set

Burner

Pressure

Reducing

Valve

Pressure

Reducing

Valve

Stop

Valve

Storage Tank

Below Ground

For

Fuel Tanks

above

Pump Set

(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).

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.1 Electrical Supply

A 230 V 50 Hz 1 Ø supply is required for all heater

Models 015 to 030 connected to the heater terminals

L1, N and Earth.

Standard models 040 to 0100 and all High Flow

models require a 400 V 50 Hz 3 Ø and neutral

supply connected to the heater terminals L1, L2, L3,

N and Earth.

All heaters and controls must be correctly earthed.

All external wiring must comply with the relevant IEE

and local regulations and be carried out by a

qualified electrician.

It is important that "L and N" polarity is correct for

these heaters, as incorrect polarity may prevent the

burner control box from operating properly. It is also

important that the voltage between N and earth is at

0 V and can never exceed 15 V.

An isolator with a contact separation of at least 3

mm on all poles should be installed adjacent to the

heater, but not attached to it, to disconnect all

supplies to the heater and where necessary to

isolate the remote control panel.

The final connection to the heater should be made in

metal sleeved flexible cable or flexible conduit to the

main terminal block under the front lower panel of

the heater using 1 sq. mm cable. Model 0100 and

High Flow models with 5.5kW or 7.5kW motors use

1.5 sq. mm cable. Cable entry is provided into the

rear horizontal frame of the cabinet.

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.

9.2.2 Positioning Room Thermostats or

Roberts-Gordon Control

A room thermostat or Roberts-Gordon control

should be mounted on a wall or column at a height

of approximately 1.5-1.8 metres from the floor to

measure the ambient temperature. It should be clear

of both cold draughts and the direct path of warm air

from the heater.

9.2.3 Remote Frost Thermostat

When required, connect to terminals 2 and 3 in the

main terminal block.

Locate the thermostat within the heated space

adjacent to the most vulnerable equipment that

requires protection.

See Page 20, Section 9.3 through Page 27, Section

9.10.

9.2.4 Controls for High/Low Burner Operation

For heaters with a high/low burner, the controls will

need to provide two stage signal to operate these

burners. This is best provided by a two stage

thermostat.

The thermostat may control the heater outlet

temperature if the heater is designed for a duct

distribution system or the room temperature.

The site wiring will be across terminals 2 and 3 for

any time control and the on/off function of the burner

(stage two), and across terminals 7 and 8 for the

high fire (first stage) setting.

The burner will then operate as follows:

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.

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.

WARNING

Electrical Shock Hazard

Disconnect electrical power before servicing.

Failure to follow these instructions can result in

death or electrical shock.

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)

Note: Remote fan control

carries full load of fan motor

7 amp inductive

Red

10 A

Red / White

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

230 V 50 Hz

1 PH SUPPLY

Red / White

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

Blue

Red

FAN

LIMIT

FAN / LIMIT STAT

Brown

PACKAGED

BURNER

B4 S3 T2 T1 NL1

GAS BURNER 7 WAY PLUG

1 mm Ø Red Tri Rated Flex Cable

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.4 CCH Wiring Diagram Oil Models 15-30 (floor standing)

Note: Remote fan control

carries full load of fan motor

7 amp inductive

Red

10 A

Red / White

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

230 V 50 Hz

1 PH SUPPLY

Red / White

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

Blue

Red

FAN

LIMIT

FAN / LIMIT STAT

Brown

PACKAGED

BURNER

S3 T2 T1 NL1

OIL BURNER 6 WAY PLUG

1 mm Ø Red Tri Rated Flex Cable

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.5 CCH Wiring Diagram Gas Models 15-30 (horizontal mounting)

Red

10 A

MAIN TERMINALS

IN CONTROL PANEL

Blue

PACKAGED

BURNER

FANLIMIT

FAN / LIMIT STAT

Brown

R1 COIL 240v

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

REMOTE LOCKOUT

RESET

FOR BURNERS WITH

LANDIS & STEFA

CONTROL BOX

(GAS-FIRED)

REMOTE LOCKOUT

LAMP 230V

MAIN FAN

MOTOR

OUTPUTS

FROM

BURNER

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

B4 S3 T2 T1 NL1

GAS BURNER 7-WAY PLUG

Red / White

Red

Red / White

Blue

230 V 50 Hz

1 PH SUPPLY

FOR GAS BURNER

T1 IS NOT USED

B4 = BURNER RUN TO R1 COIL

ALL OTHER WIRES SAME AS OIL

BURNER

1 mm Ø RED TRI RATED FLEX CABLE

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.6 CCH Wiring Diagram Oil Models 15-30 (horizontal mounting)

Red

10 A

MAIN TERMINALS

IN CONTROL PANEL

Blue

PACKAGED

BURNER

FANLIMIT

FAN / LIMIT STAT

Brown

R1 COIL 240v

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

REMOTE LOCKOUT

RESET

REMOTE LOCKOUT

LAMP 230V

MAIN FAN

MOTOR

OUTPUTS

FROM

BURNER

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

Red / White

Red

Red / White

230 V 50 Hz

1 PH SUPPLY

1 mm Ø RED TRI RATED FLEX CABLE

S3 T2 T1 NL1

OIL BURNER 6-WAY PLUG

FOR BURNERS WITH

SATRONIC CONTROL BOX

(OIL-FIRED)

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.7 CCH Wiring Diagram Gas Models 40-50 (floor standing)

Red

10 A

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

Blue

Red

FANLIMIT

FAN / LIMIT STAT

PACKAGED

BURNER

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

B4 S3 T2 T1 NL1

GAS BURNER 7-WAY PLUG

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.8 CCH Wiring Diagram Oil Models 40-50 (floor standing)

Red

10 A

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

Blue

Red

FANLIMIT

FAN / LIMIT STAT

S3 T2 T1 NL1

OIL BURNER 6-WAY PLUG

PACKAGED

BURNER

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.9 CCH Wiring Diagram Gas Models 40-50 (horizontal mounting)

Red

10 A

FANLIMIT

FAN / LIMIT STAT

R1 COIL 240v

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

PACKAGED

BURNER

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

OUTPUTS

FROM

BURNER

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

Blue

Red / White

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

B4 S3 T2 T1 NL1

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

REMOTE LOCKOUT

RESET

FOR BURNERS WITH

LANDIS & STEFA

CONTROL BOX

(GAS FIRED)

REMOTE LOCKOUT

LAMP 230V

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.10 CCH Wiring Diagram Oil Models 40-50 (horizontal mounting)

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.

Red

10 A

FANLIMIT

FAN / LIMIT STAT

R1 COIL 240v

FOR BURNERS WITH

SATRONIC CONTROL BOX

(OIL FIRED)

REMOTE LOCKOUT

LAMP 230V

REMOTE LOCKOUT

RESET

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

PACKAGED

BURNER

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

OUTPUTS

FROM

BURNER

S3 T2 T1 NL1

OIL BURNER 6-WAY PLUG

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

Red / White

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.11 CCH Wiring Diagram Gas Models 60-100 (floor standing)

10 A

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

FANLIMIT

FAN / LIMIT STAT

PACKAGED

BURNER

Red

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

B4 S3 T2 T1 NL1

GAS BURNER 7-WAY PLUG

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.12 CCH Wiring Diagram Oil Models 60-100 (floor standing)

10 A

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

FANLIMIT

FAN / LIMIT STAT

S3 T2 T1 NL1

OIL BURNER 6-WAY PLUG

PACKAGED

BURNER

Red

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

1 mm Ø RED TRI RATED FLEX CABLE

Red / White

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.13 CCH Wiring Diagram Gas Models 60-100 (horizontal mounting)

10 A

Blue

FANLIMIT

FAN / LIMIT STAT

R1 COIL 240v

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

PACKAGED

BURNER

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

OUTPUTS

FROM

BURNER

Red

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

Red / White

Blue

1 mm Ø RED TRI RATED FLEX CABLE

REMOTE LOCKOUT

RESET

FOR BURNERS WITH

LANDIS & STEFA

CONTROL BOX

(GAS-FIRED)

REMOTE LOCKOUT

LAMP 230 V

B4 S3 T2 T1 NL1

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

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.

SECTION 9: WIRING AND ELECTRICAL INFORMATION

9.14 CCH Wiring Diagram Oil Models 60-100 (horizontal mounting)

10 A

Blue

FANLIMIT

FAN / LIMIT STAT

R1 COIL 240v

FOR BURNERS WITH

SATRONIC CONTROL BOX

(OIL-FIRED)

REMOTE LOCKOUT

LAMP 230V

REMOTE LOCKOUT

RESET

TIME/TEMPERATURE

CONTROLS

FAN CONTROL

(OPTIONAL)

PACKAGED

BURNER

LOCKOUT SIGNAL

BURNER RUN SIGNAL

LOCKOUT RESET SIGNAL

OUTPUTS

FROM

BURNER

S3 T2 T1 NL1

OIL BURNER 6-WAY PLUG

Red

MAIN

FAN

MOTOR

MAIN TERMINALS

IN CONTROL PANEL

Red

Grey

Black

Brown

CONTACTOR

400 V 50 Hz

3 PH SUPPLY

Blue

Red

Red / White

1 mm Ø RED TRI RATED FLEX CABLE

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

9.15 Final Connections to Ecoflam HIGH/LOW or Modulating Burners (all models)

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.

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.

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 dia-

grams on Page 20, Section 9.3 through Page

32, Section 9.15.

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

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.

WARNING

Electrical Shock Hazard

Use extreme caution while commissioning.

Failure to follow these instructions can result in

death or electrical shock.

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.

Less Than

0.1 ohm

ohm

230v 50Hz AC

(must be less than 15v)

Supply

Earth

Terminal

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 13: Combination Thermostat (all models)

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.

10.2.1 Gas Supply

All aspects of the gas installation, including the gas

meter, must be inspected, tested for soundness and

purged in accordance with local and national codes.

Ensure that the air is fully purged from the heater

inlet pipe up to the main gas valve inlet test nipple.

10.2.2 Before Operating the Heater

Ensure the burner head, air damper and pressure

switch settings are adjusted for the correct burner in

accordance with the Data Tables on Page 8, Section

4.4 through Page 10, Section 4.7 (see the burner

reference letter on data plate).

To ensure that all the controls are in safe working

order, operate the heater for the first time with the

isolating gas valve turned off.

1. Turn off the gas isolating valve

2. Using the installed external control, turn on the

burner. The automatic sequence will now begin

as described on Page 35, Figure 14.

There will be no ignition of the burner and lockout

will occur, which proves the controls are operating

correctly.

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 gover-

nor for models 015 to 030) 3 turns clockwise.

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.

3. Adjust the main gas burner pressure to the

value given in the relevant Data Table for the

model concerned using the Main Gas Regula-

tor (accessed under the swivel cover). See

Page 37, Figure 17.

The results of setting the gas flow rate by using

burner pressure only can lead to quite wide

variations in heat input due to the nature of the

burners used.

NOTE: If the correct burner pressure cannot be

reached, then check the inlet pressure to the valve,

with the burner firing. See Technical Data Tables on

Page 8, Section 4.5 for inlet pressure requirements.

Do not continue to adjust the regulator if the

pressure is not changing.

If the inlet pressure is too low to allow the correct

burner pressure setting, then the gas inlet pressure

must be corrected before completing the

commissioning.

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.

C°

100

120

Set Point 1

Fan Off

Set to 38°C

Set Point 3

Limit

Set to 110°C

Set Point 2

Fan On

Set to 60-65°C

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.

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".

NOTE: If the pressure switch contacts (normally

closed) are open, the heater will not start.

2. The combustion air fan turns on and the pres-

sure 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 estab-

lished, 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 sta-

ble.

7. The start gas runs for ten seconds, then the

main gas valve opens. The control is now in its

normal run position

Figure 14: Gas-Fired Heater Control Box Sequence

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.

Thermostat

Motor

Pressure Switch

Transformer

Gas Valve

Ionization Probe

Necessary Input Signal

Output Signal of the Device

30 s 3 s

2 s

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

Figure 15: Motor Starter (models 040 -100 and Thermal Overload (models 060 - 100)

Figure 16: Gas Train Circuit for Dungs Gas Valves (all models)

Line Connections

Load Connections

Contactor

Thermal

Overload

Reset Button

Overload

Connection

Overload Scale

(motor current amps)

Overload

Adjusting Level

Wire Connecting

Overload Switch to Coil

Models 15 to 30 - All types of valve Models 40 to 100 - All types of valve

To B urner To B urner

Burner

Flange Union

Automatic

Gas Valve &

Regulator

Automatic

Gas Valve &

Regulator

Gas

Inlet

Gas

Inlet

Automatic

Gas Valve

Automatic

Gas Valve

Automatic

Gas Valves

1 = Start Gas

2 = Main Gas

TP1 TP1

TTT

TP2 TP2

TP3 TP3

TP1 = Inlet Pressure

TP2 = Pressure between Main Gas Valves

TP3 = Valve Outlet Pressure

Burner Pressure TP on Burner

NOTE: Orifice plate

fitted into union

between valve and

burner where required.

NOTE: Orifice plate

fitted into union

between valve and

burner for models

40/50, and burner flange

for models 60 and over.

Regulator

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 shut-

off 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 counter-

clockwise 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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

10.5.1 Pressure Switch

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.

10.5.3 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.

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

WARNING

Electrical Shock Hazard

Use extreme caution while commissioning.

Failure to follow these instructions can result in

death or electrical shock.

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

Table 2: Error Diagnosis

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.

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

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.

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.

Flash-Code Key Message Flash-Code

Short Pulse l

Long Pulse l

Short Pause .

Long Pause _

Pre-ignition

tv1

l l l l .

Safety Time

tv2

l l .

Delay Time to Valve V2

tv2

l l l .

Running l _

Low Mains Voltage l l l _

Error Message Flash-Code Possible Fault

Lockout l l l l l Within lockout safety time,

no flame established.

Stray Light l l l l l

Stray light during monitor

phase, detector may be

faulty.

Flash-Code for Manual Lockout

Manual/External

Lockout l l l l l _ l l l l l

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.

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

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

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

WARNING

Electrical Shock Hazard

Disconnect electrical power before servicing.

Failure to follow these instructions can result in

death or electrical shock.

RUN ON

DOWN

THERMOSTAT

CALL FOR

HEAT

BURNER

RUN

FAN

2-3 MINUTES

White fan button

Pull out for normal operation.

Press in for constant fan.

Red limit reset button

(Press to reset)

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.

If the air flow is reduced due to power failure, the

limit thermostat will cause the burner to lockout.

Description Part Number

Combination Fan/Limit Thermostat K017A

SECTION 11: USER INSTRUCTIONS

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 con-

trols 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.

11.3.2 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.

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 electri-

cal supply or failure of the distribution fan.

5. The burner supply plug has been discon-

nected.

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 oil-

fired 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.

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.

Explosion Hazard

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

WARNING

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 suppliers

instructions.

7. If you cannot reach your gas

supplier, call the Fire Department.

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.

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.

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.

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

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.

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.

Motor

Pulley

Fan

Pulley

8 mm to 10 mm

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 oil-

fired 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.

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.

Replace fan/limit

thermostat.

See Figure 13 to check

thermostat settings. No

Use 14.6 or 14.7 to test fan.

Ye s

Check external controls are

ON and the fuse in the

burner is sound.

Test burner as in

14.2 (oil-fired),

14.3 (gas-fired).

Repair or Replace.

Ye s

Check if the control fuse in

the heater has blown.

Ye s

Is the 'lockout' button on the

burner alight?

Test burner as in

14.2 (oil-fired),

14.3 (gas-fired).

Heater Operating

TROUBLESHOOT ENDS.

Press in the white button on

fan/limit thermostat.

Does the burner stop after

running for several minutes

with controls still ON ?

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Did burner 'lockout' ?

Check main fan for blockage

or belt tension and correct

rotation.

Check operation and setting

of fan/limit thermostat. Repair

or replace as necessary.

START

Assuming fuel & electrical

supplies are ON

Ye s

Does the burner fire?

Does the main fan run?

For your safety and optimum heater performance, use only ROBERTS GORDON® replacement parts.

Conduct Commissioning procedure as shown on Page 33, Section 10.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

14.2 Troubleshooting for Oil Burners (see manufacture’s instructions)

Heater Operating

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Check oil solenoid valve.

Check ignition electrodes are

set as in the manufacturer's

instructions, the fuel supply

and nozzle.

Ye s

Does the burner control

box 'lockout' after 15

seconds?

Control box faulty.

Repair or replace.

Use Section 14.4 to

trace fault.

Ye s

Does the burner control

box 'lockout' before 15

seconds?

Repair or replace.

Check control box.

Check supply to burner

motor.

Ye s

Check if the control fuse in

the heater has blown.

Disconnect photo cell

and try again.

Ye s

Did the burner fire?

Ye s

START

Assuming fuel & electrical

supplies are ON

Ye s

Does the burner fire?

Use Section 14.4 to

trace fault.

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.

For your safety and optimum heater performance,

use only ROBERTS GORDON® replacement parts.

Conduct Commissioning procedure as shown

on Page 33, Section 10.

SECTION 14: TROUBLESHOOTING

14.3 Troubleshooting for Gas Burners (see manufacturer’s instructions)

Heater Operating

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Check main gas valves and

wiring.

Ye s

Does main gas fire?

Ye s

Does 'lockout' occur?

Check ignition circuit, fuel

supply and gas solenoid

valves.

Ye s

Does the burner fire?

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.

Check settings

pressure switches.

Fault lies elsewhere.

Ye s

Does the burner control

box 'lockout' after 10

seconds?

Use Section 14.4 to check

the flame

monitoring system.

Use Section 14.4 to check

the flame

monitoring system.

Ye s

Does the burner control

box 'lockout' before 10

seconds?

See Section 10.5.1 for

setting.

Is the pressure switch

at rest?

(no contact open)

Ye s

START

Assuming fuel & electrical

supplies are ON.

Ye s

Does the burner fan run?

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.

COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL

14.4 Troubleshooting for Flame Supervision System

Heater Operating

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Control box faulty.

Replace with correct type.

Ye s

'Lockout' still occurs?

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.

Ye s

Does 'lockout' occur when

a flame is present?

Repair or replace.

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.

Ye s

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?

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 Gas-Fired

Maximum flame

current with no

flame

Minimum flame

current with

flame

Maximum flame

current with no

flame

Minimum flame

current with

flame

12 µ Amp 25 µ Amp 0.5 µ Amp 1.0 µ Amp

14.5 Troubleshooting for Solenoid Valves Circuit

14.6 Troubleshooting for Main Fan Circuit (1 Ø)

Fault lies elsewhere.

Investigate and correct.

Valve faulty.

Replace with correct type.

Ye s

Is there an electrical supply

to the valve terminals?

Valve faulty.

Replace with correct type.

Fault lies elsewhere.

Investigate and correct.

Valve Operating

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Ye s

Does valve open at the

correct time? No

Ye s Ye s

START

Is there pressure on the

outlet of the valve when the

valve should be closed?

Is there an electrical supply

to the valve terminals?

Motor running.

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Thermal overload in motor

is faulty.

Replace complete fan unit.

Ye s

Motor stops after running

some time.

Fan thermostat faulty.

Replace and reset.

Check calibration of the

fan thermostat.

The dial should indicate

the approximate

temperature of the

sampled air.

Fault lies elsewhere.

Ye s

Re check supply to

terminals L1 to N.

Ye s

Check the setting of the

fan thermostat as in

Figure 13.

Ye s

Check and test wiring to

motor. Does the motor run

now?

Motor faulty.

Replace complete fan unit.

Ye s

START

NoNo

Main fan will not operate

following warm up

period of heat exchanger.

Check for 230 V

at terminals 1 to N.

Press in white button

of fan/limit thermostat

and retest.

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)

Motor running.

TROUBLESHOOT ENDS.

If problems persist, contact

ROBERTS GORDON® at

Tel: +44 (0)121 506 7709

www.rg-inc.com

Thermal overload in motor

is faulty.

Replace complete fan unit.

(direct drive fans only)

Motor faulty.

Replace complete fan unit.

Contactor or overload faulty.

Replace as necessary.

Check and test wiring to

motor.

Ye s

Check for 400 V three phase

at input and output of

contactor.

Ye s

Does fan run now?

Motor stops after running

some time.

Reset thermal overload

and check setting. See

page 28, Section 10.1.6.

Check for 230 V at coil

terminals

of fan contactor.

Fan thermostat faulty.

Replace and reset.

Check calibration of the

fan thermostat.

The dial should indicate

the approximate

temperature of the

sampled air.

Ye s

Check the setting of the

fan thermostat as in

Section 5.1.

Fault lies elsewhere.

Ye s

Press in white button

of fan/limit thermostat

and retest.

Ye s

Check for 230 V at terminals

1 to N

Ye s

START

Main fan will not operate

following warm up

period of heat exchanger.

Check for 400 V three phase

supply at main terminals.

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.

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.

15.2 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 con-

tactor from the panel.

4. Reverse these instructions to refit. Check rota-

tion 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

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.

15.4 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 push-

ing 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.

15.5 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 ensur-

ing 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.

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

Dial

Set Point 3 Limit Temp.

Set Point 1 Fan Off

Set Point 2 Fan On

Fan Terminals

Manual Fan Switch

(White)

BREAK-OFF LINK

MUST BE REMOVED

Limit Terminals

Limit Stat

Manual

Reset Button

(Red)

Push in Lock

Wire to Controlled Equipment

Push Screwdriver in

and hold to release

Pull out for normal operation.

Push in for continuous fan.

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.

ROBERTS GORDON®

thermostats do not have a

break-off link. Remove

break-off link if thermostat

was not provided by

Roberts-Gordon.

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.

16.1 Spare Parts List

Part No. Description

015

020

030

040

050

060

070

080

0100

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 136A49 Vee Belt -----2222

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

WARNING

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.

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).

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.

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.

IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,

FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER

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.

TO TURN OFF THE HEATER

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

Roberts-Gordon Europe Limited

Unit A, Kings Hill Business Park

Darlaston Road, Wednesbury

West Midlands WS10 7SH UK

Telephone: +44(0)121 506 7700

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.

Telephone: 716.852.4400

Fax: 716.852.0854

Toll Free: 800.828.7450

Clearances to Combustibles

Installation Clearances

.6 m .6 m

.6 m

4 m

.6 m

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

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