Page 3 - TABLE OF CONTENTS
© 200 8 Ro b erts-Gordon LLC All rights reser v ed. N o part of this w ork co v ered b y the copyrights herein may b e reprod u ced or copied in any form or b y any means - graphic, electronic, or mechanical, incl u ding photocopying, recording, taping or information storage and retrie v al systems ...
Page 5 - TABLE OF FIGURES; Figure 1: Installation Clearances and Clearances to
TABLE OF FIGURES Figure 1: Installation Clearances and Clearances to Combustibles ............................................................. 4 Figure 2: Typical Installation of a Gas Fired Cabinet Heater ... 11Figure 3: Typical Installation of a Oil-Fired Cabinet Heater ..... 12Figure 4: Flue Ter...
Page 8 - COMBAT; SECTION 1: HEATER SAFETY; * Halogenated Hydrocarbons; National Standards and Applicable Codes; CAUTION; Do not use heater in an area containing corrosive
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 2 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 fo...
Page 9 - Location and Suspension; through Figure 5; Clearances to Combustibles; Section 9
SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSIDERATIONS3.1 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 mo...
Page 10 - WARNING; Fire Hazard; The flue pipe must have clearance from combustibles by 5 cm.
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 4 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, li q uids and vapours th...
Page 11 - Dimension Data - PGP & POP Internal Heaters; Front View; Model
SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIFICATIONS4.1 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 th...
Page 12 - Dimension Data - PGP & POP External Heaters
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 6 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 ...
Page 13 - Air Outlet and Flue Arrangements
SECTION 4: S PECIFICATIONS 7 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 st...
Page 14 - Appliance Category II
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 8 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 elec...
Page 15 - For adjustment of head setting, see Ecoflam Instructions.
SECTION 4: S PECIFICATIONS 9 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 ...
Page 17 - Figure 2: Typical Installation of a Gas Fired Cabinet Heater
SECTION 5: H EATER I NSTALLATION 11 SECTION 5: HEATER INSTALLATION5.1 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...
Page 18 - Figure 3: Typical Installation of a Oil-Fired Cabinet Heater
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 12 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 ...
Page 19 - Flues must be correctly sized for the model.; Figure 4: Flue Termination
SECTION 6: F LUE I NSTALLATION 13 SECTION 6: FLUE INSTALLATION6.1 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 ...
Page 20 - Figure 7: Socket Direction
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 14 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 adequatesupport toprevent heaterfrom carrying...
Page 21 - Isolated Equipment Rooms
SECTION 7: A IR S UPPLY 15 SECTION 7: AIR SUPPLY7.1 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 Is...
Page 22 - SECTION 8: FUEL PIPING; • Gas supply pipe is run in medium or heavy; Figure 10: Gas Connection
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 16 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 Compa...
Page 23 - See Page; Max
SECTION 8: F UEL P IPING 17 8.2 Fuel Oil Supply8.2.1 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 ...
Page 24 - Figure 12: Pressurised System Installation - Duplex System
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 18 Figure 12: Pressurised System Installation - Duplex System Check V al v e Check V al v e Relief V al v e Press u re Ga u ge Check V al v e Stop V al v e Stop V al v e Stop V al v e B u rner N o. 1 P u mp N...
Page 25 - through Page 27, Section; Controls for Fully Modulating Burners; The burner will fire. When the burner sequence; NIN; k H
SECTION 9: W IRING AND E LECTRICAL I NFORMATION 19 SECTION 9: WIRING AND ELECTRICAL INFORMATION9.1 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...
Page 26 - The control will then adjust the burner input; hit
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 20 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, t...
Page 28 - GAS BUR
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 22 9.5 CCH Wiring Diagram Gas Models 15-30 (horizontal mounting) Red 1 2 3 4 N 10 A MAI N TERMI N ALS I N CO N TROL PA N EL Bl u e Bl u e Bl u e L L L 1 2 3 PACKAGEDBUR N ER FA N LIMIT FA N / LIMIT STAT Bro w...
Page 29 - OIL BUR
SECTION 9: W IRING AND E LECTRICAL I NFORMATION 23 9.6 CCH Wiring Diagram Oil Models 15-30 (horizontal mounting) Red 1 2 3 4 N 10 A MAI N TERMI N ALS I N CO N TROL PA N EL Bl u e Bl u e Bl u e L L L 1 2 3 PACKAGEDBUR N ER FA N LIMIT FA N / LIMIT STAT Bro w n 7 8 2 7 R1 COIL 240 v 3 1 LOCKOUT SIG N A...
Page 39 - SECTION 10: COMMISSIONING; through Page; Cut Hazard
SECTION 10: C OMMISSIONING 33 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...
Page 40 - See
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 34 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 usin...
Page 41 - Figure 14: Gas-Fired Heater Control Box Sequence
SECTION 10: C OMMISSIONING 35 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 instruction...
Page 42 - Figure 16: Gas Train Circuit for Dungs Gas Valves (all models); Models 15 to 30 - All types of valve; bu
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 36 Figure 15: Motor Starter (models 040 -10 0 and Thermal Overload (models 060 - 10 0) Figure 16: Gas Train Circuit for Dungs Gas Valves (all models) Line Connections Load Connections Contactor ThermalO v erl...
Page 43 - Figure 17: Dungs Gas Valve; for the position of the burner
SECTION 10: C OMMISSIONING 37 Figure 17: Dungs Gas Valve 10.4 Gas ValvesDungs 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 ...
Page 44 - Preparation for Burner Pressure Test
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 38 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 f...
Page 45 - See Table 1; Table 1: Fault Display; see; External Controls; warnings defined in this manual.; Message; l l l
SECTION 10: C OMMISSIONING 39 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 ...
Page 46 - See Page 41, Section; Figure 19: Heater Operating Sequence; Section; Modulating Operation; Pull out for normal operation.; Red limit reset button
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 40 SECTION 11: USER INSTRUCTIONS11.1 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 ...
Page 47 - Dan
SECTION 11: U SER I NSTRUCTIONS 41 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...
Page 49 - Burner Maintenance; Motor
SECTION 12: S ERVICING 43 SECTION 12: SERVICING12.1 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 t...
Page 50 - All COMBAT; Burner Conversion
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 44 SECTION 13: CONVERSION BETWEEN FUELS13.1 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...
Page 51 - ARNING; Conduct Commissioning procedure as shown
SECTION 14: T ROUBLESHOOTING 45 SECTION 14: TROUBLESHOOTING14.1 General W ARNING Explosion Hazard Installation must be done by a registered installer / contractor q ualified in the installation and service of gas - fired heating e q uipment or your gas supplier. Failure to follow these instructions ...
Page 54 - Troubleshooting for Flame Supervision System
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 48 14.4 Troubleshooting for Flame Supervision System Heater Operating TROUBLESHOOT ENDS. If pro b lems persist, contact ROBERTS GORDO N ® at Tel: +44 (0)121 506 7709 www .rg-inc.com N o Control b ox fa u lty....
Page 55 - Troubleshooting for Solenoid Valves Circuit
14.5 Troubleshooting for Solenoid Valves Circuit 14.6 Troubleshooting for Main Fan Circuit (1 Ø) Fa u lt lies else w here. In v estigate and correct. V al v e fa u lty. Replace w ith correct type. Yes N o Is there an electrical s u pply to the v al v e terminals? V al v e fa u lty. Replace w ith cor...
Page 56 - Conduct Commissioning procedure as
14.7 Troubleshooting for Main Fan (3 Ø) Motor r u nning. TROUBLESHOOT ENDS. If pro b lems persist, contact ROBERTS GORDO N ® at Tel: +44 (0)121 506 7709 www .rg-inc.com N o Thermal o v erload in motor is fa u lty. Replace complete fan u nit. (direct dri v e fans only) Motor fa u lty. Replace complet...
Page 57 - Burner Components
SECTION 15: R EMOVAL AND R EPLACEMENT P ARTS 51 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 ...
Page 58 - Check the correct rotation of the fan as; Figure 22: Combination Fan/Limit Thermostat; ROBERTS GORDON
COMBAT ® C ABINET H EATERS I NSTALLATION , C OMMISSIONING , O PERATION AND S ERVICE M ANUAL 52 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 Thermo...
Page 59 - SECTION 16: PARTS LIST; A49 Vee Belt
SECTION 16: P ARTS L IST 53 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 burn...
Page 62 - Attach this information to the wall near the ROBERTS GORDON
WARNING © 2007 Roberts-Gordon, LLC www.r g -inc.com Printed in U.S.A. P/ N 91040095 Attach this information to the wall near the ROBERTS GORDON ® heater Read the Installation, Commissionin g , Operation and Service Manual thorou g hly before installation, operation or service. OPERATING INSTRUCTIONS...
