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. Extinguish any open flame. 6. Leave the building. 7. Immediately call your local gas supplier after leaving the building. Follow the gas supplier’s instructions. 8. If you cannot reach your gas supplier, call the Fire Department.
TABLE OF CONTENTS SECTION 1: Heater Safety...................................................... 2 1.1 Manpower Requirements ............................................. 2 1.2 Safety Labels and Their Placement ............................. 2 SECTION 2: Installer Responsibility ..................................... 4 2.1 Laminated Wall Plate ................................................... 4 2.2 Corrosive Chemicals.................................................... 4 2.
TABLE OF FIGURES Figure 1: Burner and Combustion Panel Label Placement ....... 3 Figure 2: Installation Clearances and Clearances to Combustibles ........................................................... 6 Figure 3: Typical Installation of an Gas-Fired Cabinet Heater . 15 Figure 4: Typical Installation of an Oil-Fired Cabinet Heater ... 16 Figure 5: Flue Termination ...................................................... 18 Figure 6: Offset Flues with 135° Bends...................................
Product Approval 1 of 85
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/oilfired heating equipment.
SECTION 1: HEATER SAFETY Figure 1: Burner and Combustion Panel Label Placement Description Logo Label Address Label Rating Plate Label Electrical Shock Hazard Label Severe Injury Hazard Label Burn Hazard Label Fire Hazard Label Lighting Instruction Label Wiring Diagram Models 15-30 Gas, Floor Wiring Diagram Models 40-50 Gas, Floor Wiring Diagram Models 60-100 Gas, Floor Wiring Diagram Models 15-30 Gas, Horz. Wiring Diagram Models 40-50 Gas, Horz. Wiring Diagram Models 60-100 Gas, Horz.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 2: INSTALLER RESPONSIBILITY WARNING Explosion Hazard 2.2 Corrosive Chemicals CAUTION Product Damage Hazard Equipment must have access to uncontaminated air at all times. Do not use heater in area containing corrosive chemicals. Failure to follow these instructions can result in death, injury or property damage. Refer to appropriate Material Safety Data Sheets (MSDS).
SECTION 3: CRITICAL CONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS combustibles are not indicated, then installation clearances apply. Check the clearances on each heater for the model heater being installed to make sure the product is suitable for your application and the clearances are maintained. Read and follow the safety guidelines below: • Keep petrol or other combustible materials including flammable objects, liquids, dust or vapours away from this heater or any other appliFire Hazard ance.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 2: Installation Clearances and Clearances to Combustibles .6 m (2') *.6 m (2') 4 m (13.2') .6 m (2') *.6 m (2') *.6 m (2') 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.
SECTION 3: CRITICAL CONSIDERATIONS 3.6 Electrical Supply DANGER Electrical Shock Hazard Disconnect electric before service. Heater must be properly grounded. Failure to follow these instructions can result in death or electrical shock. 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 MGB and MOB 040 and 050 models are available as belt drive).
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 4: SPECIFICATIONS 4.
SECTION 4: SPECIFICATIONS 4.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.3 Air Outlet and Flue Arrangements 4.3.1 Vertical and Horizontal Heaters - Free Blowing (top view) 040 030 015/020 165 165 0100 060/070/080 050 229 203 184 284 NOTE: Models 015-020 are fitted with 229 mm (9") diameter discharge heads as standard. Models 030-0100 are fitted with 356 mm (14") diameter discharge heads as standard. 4.3.
SECTION 4: SPECIFICATIONS 4.4 General Technical Data Table (all models) Appliance Category II 2H/L 3B/P Model 015 020 030 Electrical Supply* Main Fan Motor Type Motor Size (kW) Motor Pulley (PCD) NA Fan Pulley (PCD) NA Start Current Run Current Airflow Free Blowing 040 050 230 V / 50 Hz / 1 Ø Direct Drive 0.75 (Amps) (Amps) (m3/h) (ft3/min) 24 5.3 3398 2000 24 5.3 3398 2000 2.2 28 6.3 5097 3000 21 6.2 6796 4000 21 6.2 8495 5000 060 070 080 0100 400 V / 50 Hz / 3 Ø Belt Drive 1.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.6 Technical Data - Ecoflam 2-Stage Burners Model Maximum Gross Heat Input Maximum Net Heat Input Minimum Gross Heat Input Minimum Net Heat Input Maximum Heat Output Minimum Heat Output Pressure Switch Setting Gas Connection (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (mbar) (in) 020 030 040 050 060 070 080 0100 73.3 250.1 66.
SECTION 4: SPECIFICATIONS 4.7 Technical Data - Ecoflam Oil-Fired Burners Model Gross Heat Input Heat Output (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) Burner Type Oil Pump Connections 015 020 030 040 050 060 070 080 0100 55.5 189.4 47.4 161.8 MAX 8 73.3 250.1 61.2 208.9 MAX 8 93.2 318.0 78.4 267.4 MAX 12 129.9 443.2 110.2 375.9 MAX 15 162.0 552.7 134.5 458.8 MAX 15 3/8 208.0 709.7 177.7 606.5 MAX 20 242.0 825.7 205.3 700.3 MAX 20 275.2 939.0 230.4 786.2 MAX 30 348.5 1189.1 293.4 1001.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 4.8 Technical Data - Ecoflam 2-Stage Oil Burners Model Maximum Gross Heat Input Maximum Net Heat Input Minimum Gross Heat Input Minimum Net Heat Input Maximum Heat Output Minimum Heat Output (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) (kW) (Btu/h) x (1000) 030 040 050 060 070 080 0100 93.2 318.0 84.0 286.6 65.2 222.5 58.8 200.6 77.1 263.0 55 188 129.
SECTION 5: HEATER INSTALLATION SECTION 5: HEATER INSTALLATION WARNING Crush Hazard Use proper lifting equipment and practices. Falling Hazard Use proper safety equipment and practices to avoid falling. Severe Injury Hazard Cut/Pinch Hazard Use proper lifting practices and equipment. Wear protective gear during installation, operation and service. Equipment and accessories are heavy. Edges are sharp. Failure to follow these instructions can result in death, injury or property damage. 5.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 4: Typical Installation of an Oil-Fired Cabinet Heater *Only single wall stainless steel flue is to be used on oil-fired cabinet heaters.
SECTION 6: FLUE INSTALLATION SECTION 6: FLUE INSTALLATION 6.1 Flue Installation WARNING Carbon Monoxide Hazard Heater must be vented. Heater must be installed according to the installation manual. Failure to follow these instructions can result in death or injury. WARNING Fire Hazard Keep all flammable objects, liquids and vapours the minimum required clearances to combustibles away from heater. Some objects will catch fire or explode when placed close to heater.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 6: Offset Flues with 135° Bends Figure 5: Flue Termination Description Flue Adapter (100 mm) Flue Adapter (130 mm) Part Number 90501018K 90501019K 6.2 Type B22 Appliance The flue must terminate outside the building and be fitted with a low resistance terminal. See Page 15, Figure 3 through Page 16, Figure 4.
SECTION 6: FLUE INSTALLATION Figure 7: 90° Horizontal Flue Figure 9: Socket Direction (Stainless Steel) Figure 8: Guy Wire Figure 10: Flue and Roof Detail (Stainless Steel) 19 of 85
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 11: Flue Installation (Models 15 - 100) 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 6: FLUE INSTALLATION Figure 13: Balanced Flue (Horizontal) Model 15 (100 mm) 30 - 50 (130 mm) Concentric Flue Diameter 150 mm 200 mm 21 of 85
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 7: AIR SUPPLY WARNING Explosion Hazard Equipment must have access to uncontaminated air at all times. Failure to follow these instructions can result in death, injury or property damage. 7.1 Room Sealed Installation When installed as a room sealed heater, the air for combustion is drawn in from outside the building.
SECTION 8: FUEL PIPE WORK SECTION 8: FUEL PIPE WORK 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.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 14: Gas Connection 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.
SECTION 8: FUEL PIPE WORK 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 pressurised 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 Figure 15: B. M. Oil Lifter after the manual isolating valve.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 16: Pressurised System Installation - Duplex System Pressure Gauge Relief Valve Check Valve Check Valve Stop Valve Stop Valve For Fuel Tanks above Pump Set No. 1 Pump Stop Valve Pressure Reducing Valve No. 2 Pump Stop Valve Burner Duplex Pump Set Check Valve Storage Tank Below Ground (The system shown has one pump for run and the other for standby.
SECTION 9: WIRING AND ELECTRICAL INFORMATION SECTION 9: WIRING AND ELECTRICAL INFORMATION It should be clear of both cold draughts and the direct path of warm air from the heater. DANGER Electrical Shock Hazard 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 28, Section 9.3 through Page 39, Section 9.14.
28 of 85 BLUE N BLUE PRESSURE SWITCH 4.8 MBAR (1.96"W.C) BROWN L1 4 3 1 R N.O 2 1 P.S N.O R N.C 5 L1 BLUE RELAY R BLUE LOCKOUT BROWN BROWN 6 N N L1 N T1 L1 T1 T1 T2 L1 N T2 T2 S3 BROWN FLAME LAMP L1 T1 N T2 LIVE GROUND NEUTRAL BURNER RUN SIGNAL S3 LOCK-OUT LAMP B4 7 POLE PLUG 7 POLE SOCKET NOTES: PACKAGED BURNER 1. CONTROL WIRE TO BE A MINIMUM OF 1 mm2Ø ,FLEXING TYPE, HAVING A TEMPERATURE RATING OF A LEAST 105°C AND 600V OR EQUIVALENT.
BLUE N BLUE PRESSURE SWITCH 4.8 MBAR (1.96"W.C) BROWN L1 4 1 3 1 R N.O P.S N.O 5 2 R N.C R BLUE LOCKOUT BROWN BLUE BROWN RELAY 6 L1 N T2 T1 N T2 T1 N 7 POLE PLUG L1 S3 S3 L1 B4 7 POLE SOCKET L1 N T1 T2 S3 B4 L1 LIVE GROUND N NEUTRAL S3 LOCK-OUT LAMP T2 BURNER RUN SIGNAL T1 B4 FLAME LAMP NOTES: PACKAGED BURNER 1. CONTROL WIRE TO BE A MINIMUM OF 1 mm2Ø ,FLEXING TYPE, HAVING A TEMPERATURE RATING OF A LEAST 105°C AND 600V OR EQUIVALENT.
30 of 85 BLUE BLUE N BLUE 1 R RELAY R1 RELAY LOCKOUT 5 BROWN BLUE BLUE 6 RED/WHITE BROWN 3 2 BLUE REMOTE BURNER LOCKOUT LIGHT 7 RED/WHITE BLUE 3 R N.O 2 1 P.S N.O R N.C 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 (221°F) and 600 V.
BLUE BLUE N R N.C 1 5 RELAY R1 BROWN BROWN BROWN 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 (221°F) and 600 V. BLUE BLUE BROWN RED/WHITE RED/WHITE BLUE LOCKOUT R RELAY 6 3 2 REMOTE BURNER LOCKOUT LIGHT 7 BLUE BLUE 3 R N.O 2 1 P.S N.
32 of 85 BLUE BLUE N 1 BLUE BROWN BROWN BROWN 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 (221°F) and 600 V. 3 R N.O 2 1 P.S N.O 4 R N.
BLUE N 1 3 1 R N.O P.S N.O 2 R N.C 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 (221°F) and 600 V. 4 FAN FAN/LIMIT STAT BLUE BROWN BROWN BROWN 5 BROWN 1 3 PHASE ONLY BROWN BROWN 6 LOCKOUT RELAY R BROWN 3 2 GREEN/YELLOW LIMIT BROWN TIME / TEMPERATURE CONTROLS M1 CONTACTOR BROWN BROWN BROWN BROWN L1 BLUE BLACK L2 PRESSURE SWITCH 4.8 mbar (1.
34 of 85 BROWN BLUE L1 N 3 1 BLUE BLUE BROWN BROWN BROWN 5 R1 RELAY BLUE BLUE R LOCKOUT BLUE RELAY 6 RED/WHITE BROWN 3 2 GREEN/YELLOW LIMIT 1 BLUE 1 M1 MAIN FAN MOTOR N 7 POLE SOCKET L1 N GROUND L1 LIVE 3. 2. PACKAGED BURNER WIRE(S) LOCATED IN FIELD. WIRE(S) LOCATED IN CONTROL PANEL. MAIN TERMINALS LOCATED IN CONTROL PANEL.
BLUE 3 1 R N.O 2 1 P.S N.O 5 FAN FAN/LIMIT STAT R BLUE RELAY R1 RELAY BLUE BLUE 7 6 LOCKOUT BLUE BROWN BROWN BROWN RED/WHITE RED/WHITE BROWN 3 B4 L1 7 POLE PLUG 7 POLE SOCKET L1 N T1 T2 S3 B4 M1 MAIN FAN MOTOR L1 LIVE GROUND BURNER RUN SIGNAL T1 N NEUTRAL T2 S3 LOCK-OUT LAMP ALL WIRING SHALL BE IDENTIFIED AT BOTH ENDS, WITH CABLE BEING IDENTIFIED WITH THE SAME TERMINAL NUMBER TO WHICH IT IS CONNECTED TO IN THE CONTROL PANEL. 3. WIRE(S) LOCATED IN FIELD.
36 of 85 BLUE BROWN 4 3 1 R N.O 2 1 P.S N.O R N.C FAN 5 BROWN BROWN BROWN LOCKOUT R RELAY BROWN 1 3 PHASE ONLY 6 3 2 BLUE BLUE BLUE BROWN GREEN/YELLOW LIMIT BROWN FAN/LIMIT STAT N.C OL TIME / TEMPERATURE CONTROLS M1 CONTACTOR 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 PRESSURE SWITCH 4.8 MBAR (1.96"W.
BLUE N 4 3 1 R N.O 2 1 P.S N.O R N.C 5 FAN BLUE BROWN BROWN BROWN BROWN BLUE LOCKOUT BLUE R RELAY 6 BROWN 1 3 2 L1 N T1 T2 LIVE GROUND NEUTRAL BURNER RUN SIGNAL ALL WIRING SHALL BE IDENTIFIED AT BOTH ENDS, WITH CABLE BEING IDENTIFIED WITH THE SAME TERMINAL NUMBER TO WHICH IT IS CONNECTED TO IN THE CONTROL PANEL. 3. WIRE(S) LOCATED IN FIELD. WIRE(S) LOCATED IN CONTROL PANEL. MAIN TERMINALS LOCATED IN CONTROL PANEL.
38 of 85 BLUE BROWN BLACK GREY 3 1 R N.O 2 1 P.S N.O 5 R N.C BROWN BROWN BROWN R1 RELAY LOCKOUT RELAY R 6 RED/WHITE BLUE BLUE BROWN BLUE 3 2 GREEN/YELLOW 1 3 PHASE ONLY REMOTE BURNER LOCKOUT LIGHT 7 RED/WHITE BLUE BLUE FAN LIMIT BROWN FAN/LIMIT STAT N.C OL TIME / TEMPERATURE CONTROLS M1 CONTACTOR 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 (221°F) and 600 V.
BLUE FAN FAN/LIMIT STAT 5 BLUE R1 RELAY LOCKOUT R RELAY BROWN 6 RED/WHITE BLUE BLUE BLUE BROWN BROWN BLUE 1 BROWN 7 POLE PLUG L1 N T1 T2 S3 B4 7 POLE SOCKET L1 N T1 T2 S3 B4 T3 T2 OVERLOAD T1 OIL BURNER 7 WAY PLUG M1 MAIN FAN MOTOR GROUND NEUTRAL L1 LIVE N BURNER RUN T1 SIGNAL T2 ALL WIRING SHALL BE IDENTIFIED AT BOTH ENDS, WITH CABLE BEING IDENTIFIED WITH THE SAME TERMINAL NUMBER TO WHICH IT IS CONNECTED TO IN THE CONTROL PANEL. 3. WIRE(S) LOCATED IN FIELD.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 10: COMMISSIONING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be required to disconnect electric from equipment. Equipment may start automatically. Equipment must be properly grounded. Installation, operation and service must be done by a trained technician only.
SECTION 10: COMMISSIONING 10.1.3 Polarity Test - 1 Ø L N V 230v 50Hz AC V 0v (must be less than 15v) Supply Earth Terminal Less Than 0.1 ohm ohm 10.1.4 Polarity Test - 3 Ø Voltage between each phase L1, L2 and L3 and Earth or Neutral should be approximately 230 V. Voltage between any 2 phases should be approximately 400 V. Test Neutral to Earth as single phase. 10.1.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 10.2.1 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. Reset the lockout button of the control box and the burner should now fire. If lockout should occur when the main gas valve energises, repeat 3 or 4 times.
SECTION 10: COMMISSIONING Figure 18: Gas-Fired Heater Control Box Sequence Always disconnect the power supply before installing or removing the control unit. Do not attempt to open or carry out repairs on the control unit. 10.3 Commissioning the Two-Stage (High/Low) Burner (gas heaters) High/Low burners have additional specific requirements. Follow the burner manufacturer's instructions and the data provided on Page 11, Section 4.4 through Page 14, Section 4.8. 10.3.1 Set Gas Rate 1.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL control ensures the safe start and stop sequence and also monitors the safe presence of a flame and burner air pressure. gas temperature falls below 125° C, increase the low fire gas setting until the temperature reaches 125° C, otherwise condensation may form. 10.3.5 Sequence of Operation - Two-Stage Burner 1.
SECTION 10: COMMISSIONING 10.5.1 Main Gas Valves Refer to the relavant Ecoflam burner and gas train installation manuals supplied with your heater 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 two-stage, the Dungs gas valve, please refer to the burner manufacturer's instructions for setting the controls. 10.5.2 Throughput Adjuster These valves have a throughput adjuster fitted to the second main gas valve.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Figure 20: Oil-Fired Heaters Control Box Sequence Always disconnect the power supply before installing or removing the control unit. Do not attempt to open or carry out repairs on the control unit. 10.8.2 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.
SECTION 10: COMMISSIONING correctly. Inspect the heater for any oil leaks and repair where necessary. 10.9 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.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 11: USER INSTRUCTIONS DANGER Electrical Shock Hazard Disconnect electric before service. Heater must be properly grounded. Failure to follow these instructions can result in death or electrical shock. WARNING Fire Hazard Keep all flammable objects, liquids and vapors the minimum required clearances to combustibles away from heater. Explosion Hazard Turn off gas supply to heater before service.
SECTION 11: USER INSTRUCTIONS 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. 11.3 Lighting Instructions (all models) 11.3.1 To Turn On Heater 1. Ensure that the electrical and gas supplies to the heater are on. Check that the on-site controls are “ON”. 11.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 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.
SECTION 12: SERVICING SECTION 12: SERVICING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be required to disconnect electric from equipment. Equipment may start automatically. Equipment must be properly grounded. Installation, operation and service must be done by a trained technician only. Do not operate with door open.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 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.
SECTION 12: SERVICING 12.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Direct-Spark Igniter Replace if there are cracked ceramics, excessive carbon residue, or erosion of the electrode. See burner manufacturer’s instructions. Thermostat There should be no exposed wire or damage to the device or wiring. See Page 27, Section 9. Support Points Make sure the heater is properly supported. Make sure the heater is placed on a firm, level, non-combustible surface that can support its weight.
SECTION 13: CONVERSION BETWEEN FUELS SECTION 13: CONVERSION BETWEEN FUELS 13.1 General All Cabinet heaters may be operated on fuel oil, natural gas or propane gas, depending on which burner type has been fitted. Any conversion between fuels must be done by a contractor qualified in the installation and service of gas or oilfired heating equipment. Conversion must be carried out in accordance with the information provided to maintain compliance with the CE product certification. 13.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 14: TROUBLESHOOTING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be required to disconnect electric from equipment. Equipment may start automatically. Equipment must be properly grounded. Installation, operation and service must be done by a trained technician only.
SECTION 14: TROUBLESHOOTING 14.1 General Conduct Commissioning procedure as shown on Page 40, Section 10.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 14.2 Troubleshooting for Oil Burners (see manufacture’s instructions) Conduct Commissioning procedure as shown on Page 40, Section 10.
SECTION 14: TROUBLESHOOTING 14.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 14.4 Troubleshooting for Flame Supervision System The flame supervision system is different for gas-fired and oil-fired heaters but may be tested in a similar way. Gas-fired heaters use a rectification flame probe to monitor the flame. Oil-fired heaters use a photo sensitive cell to monitor the flame.
SECTION 14: TROUBLESHOOTING 14.5 Troubleshooting for Solenoid Valves Circuit START Is there pressure on the outlet of the valve when the Yes valve should be closed? Is there an electrical supply Yes to the valve terminals? Fault lies elsewhere. Investigate and correct. No Valve faulty. Replace with correct type. No Does valve open at the correct time? No Is there an electrical supply Yes to the valve terminals? Fault lies elsewhere. Investigate and correct. No Valve faulty.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 14.7 Troubleshooting for Main Fan (3 Ø) START Main fan will not operate following warm up period of heat exchanger. Check for 400 V three phase No supply at main terminals. Fault lies elsewhere. Yes Check for 230 V at terminals No 1 to N Press in white button of fan/limit thermostat and retest. No Fault lies elsewhere. Yes Check calibration of the fan thermostat.
SECTION 15: REMOVAL AND REPLACEMENT PARTS SECTION 15: REMOVAL AND REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON® replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage. WARNING Severe Injury Hazard Use proper lifting practices and equipment.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL 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 41, Section 10.1.6. 15.3 Control Circuit Protection The control circuit only is protected by a 10 Amp resettable circuit breaker and does not disconnect the mains electrical supply to this appliance.
SECTION 15: REMOVAL AND REPLACEMENT PARTS Figure 24: Combination Fan/Limit Thermostat Parts List 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 or property damage. Dial Set Points 3 Limit Temp.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL SECTION 16: SPARE PARTS LIST 16.
SECTION 16: SPARE PARTS LIST Models: 20 and 30 (Gas on/off) Burner: MAX105 DESCRIPTION AIR INTAKE ROD ROD BLAST TUBE CARTER FAN SCOOP DIFFUSER IONIZATION PROBE GASKET O'RING GASKET SUPPORT PIPE FIRING HEAD HEAD CAP FAN CAPACITOR INNER ASSEMBLY MOTOR AIR PRESSURE SWITCH IGNITION TRANSFORMER GAS PRESSURE SWITCH INNER ASSY CAPACITOR NOZZLE NOZZLE NEEDLE SPARK IGNITION ELECTRODE SUPPORT BURNER COVER CONTROL BOX IONIZATION CABLE IONIZATION CABLE IONIZATION CABLE AIR INTAKE SET (2 PIECE) RG P/N TC TL TC TC TC
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 40 and 50 (Gas on/off) Burner: MAX170 DESCRIPTION GAS TRAIN MB-ZRDLE 407 CONTROL BOX BASE AIR INTAKE WAISTBAND ROD BLAST TUBE BURNER COVER PROTECTION BOX DIFFUSER FLANGE O'RING GASKET HOLDER SUPPORT PIPE FIRING HEAD HEAD CAP TOOTH TOOTH CAPACITOR IONIZATION CABLE PLUG WIELAND PLUG WIELAND INNER ASSEMBLY MOTOR AIR PRESSURE SWITCH ANTIJAMMING FILTER IGNITION TRANSFORMER GAS PRESSURE SWITCH INNER ASSY IONIZATION PROBE IG
SECTION 16: SPARE PARTS LIST Models: 60 and 70 (Gas on/off) Burner: MAX250 DESCRIPTION GAS TRAIN MB-ZRDLE 410 CONTROL BOX BASE AIR INTAKE WAISTBAND ROD BLAST TUBE BURNER COVER PROTECTION BOX DIFFUSER FLANGE O'RING GASKET SUPPORT PIPE FIRING HEAD HEAD CAP TOOTH TOOTH CAPACITOR IONIZATION CABLE PLUG WIELAND PLUG WIELAND INNER ASSEMBLY MOTOR AIR PRESSURE SWITCH ANTIJAMMING FILTER IGNITION TRANSFORMER GAS PRESSURE SWITCH INNER ASSY IONIZATION PROBE IGNITION ELECTRODE CONTROL BOX AIR INTAKE SET (2 PIECE) RG P/
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 80 and 100 (Gas on/off) Burner: MAX350 DESCRIPTION GAS TRAIN CONTROL BOX BASE IGNITION CABLE IONIZATION CABLE IONIZATION CABLE IONIZATION PROBE CAPACITOR PRESSURE PORT ANTIJAMMING FILTER IGNITION TRANSFORMER CONTROL BOX SUPPORT PIPE CONTROL BOX AIR DAMPER MOTOR IGNITION ELECTRODE AIR PRESSURE SWITCH HEAD CAP PRESSURE PORT SUPPORT ROD ROD FIRING HEAD GAS PRESSURE SWITCH MOTOR ORING HEAD SUPPORT PIPE ELBOW AIR INTAKE BL
SECTION 16: SPARE PARTS LIST 16.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 40 and 50 (Gas high/low) Burner: MAX170 DESCRIPTION GAS TRAIN MB-ZRDLE 407 CONTROL BOX BASE AIR INTAKE WAISTBAND ROD BLAST TUBE BURNER COVER PROTECTION BOX DIFFUSER FLANGE O'RING GASKET HOLDER SUPPORT PIPE FIRING HEAD HEAD CAP TOOTH TOOTH CAPACITOR IONIZATION CABLE PLUG WIELAND PLUG WIELAND INNER ASSEMBLY MOTOR AIR PRESSURE SWITCH ANTIJAMMING FILTER IGNITION TRANSFORMER GAS PRESSURE SWITCH INNER ASSY IONIZATION PROBE
SECTION 16: SPARE PARTS LIST Models: 60 and 70 (Gas high/low) Burner: MAX250 DESCRIPTION GAS TRAIN MB-ZRDLE 410 CONTROL BOX BASE AIR INTAKE WAISTBAND ROD BLAST TUBE BURNER COVER PROTECTION BOX DIFFUSER IGNITION CABLE FLANGE O'RING GASKET SUPPORT PIPE FIRING HEAD HEAD CAP TOOTH TOOTH CAPACITOR IONIZATION CABLE PLUG WIELAND PLUG WIELAND INNER ASSEMBLY MOTOR AIR PRESSURE SWITCH ANTIJAMMING FILTER IGNITION TRANSFORMER GAS PRESSURE SWITCH INNER ASSY IONIZATION PROBE IGNITION ELECTRODE CONTROL BOX AIR INTAKE SET
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 80 and 100 (Gas high/low) Burner: MAX350 Burner Head: TC/TL DESCRIPTION GAS TRAIN CONTROL BOX BASE IGNITION CABLE IONIZATION CABLE IONIZATION CABLE IONIZATION PROBE CAPACITOR PRESSURE PORT ANTIJAMMING FILTER IGNITION TRANSFORMER CONTROL BOX SUPPORT PIPE CONTROL BOX AIR DAMPER MOTOR IGNITION ELECTRODE AIR PRESSURE SWITCH HEAD CAP PRESSURE PORT SUPPORT ROD ROD FIRING HEAD GAS PRESSURE SWITCH MOTOR ORING HEAD SUPPORT PIP
SECTION 16: SPARE PARTS LIST 16.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 30 (Oil on/off) Burner: MAX12 DESCRIPTION COVER AIR INLET ROD ROD BLAST TUBE BLAST TUBE GRATE AIR DAMPER FAN SCOOP PROTECTION BOX NOZZLE HOLDER SUPPORT NOZZLE HOLDER REAR DISC DIFFUSER ELECTRODES CABLES CABLES GASKET O'RING PIPE GASKET GASKET NIPPLE PIPE PIPE HYDRAULIC SYSTEM FAN CAPACITOR PLUG WIELAND PLUG WIELAND PLUG WIELAND SOCKET WIELAND WIRING TERMINAL BOX HYDRAULIC SYSTEM FIRING HEAD FIRING HEAD MOTOR COUPLING
SECTION 16: SPARE PARTS LIST COVER CONTROL BOX THERMOWAT E-BCU 90762013 90362001 Models: 40 and 50 (Oil on/off) Burner: MAX15: DESCRIPTION ROD ROD WAISTBAND ROD WAISTBAND ROD WAISTBAND BLAST TUBE BLAST TUBE GRATE COVER PROTECTION BOX NOZZLE HOLDER SUPPORT NOZZLE HOLDER DIFFUSER ELECTRODES CABLES IGNITION CABLE FLANGE O'RING PIPE GASKET GASKET AIR DAMPER PIPE CAPACITOR PLUG WIELAND PLUG WIELAND PLUG WIELAND SOCKET WIELAND HYDRAULIC SYSTEM MOTOR COUPLING OIL PUMP ANTIJAMMING FILTER HOSES IGN TRANSFORMER O
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 60 and 70 (Oil on/off) Burner: MAX20 DESCRIPTION ROD ROD WAISTBAND ROD WAISTBAND ROD WAISTBAND BLAST TUBE BLAST TUBE GRATE NOZZLE HOLDER SUPPORT NOZZLE HOLDER DIFFUSER ELECTRODES CABLES IGNITION CABLE FLANGE O'RING PIPE GASKET GASKET AIR DAMPER PIPE CAPACITOR PLUG WIELAND SOCKET WIELAND MOTOR COUPLING OIL PUMP HOSES IGN TRANSFORMER OIL VALVE OIL VALVE COIL COIL FAN FILTER OIL PUMP SUPPORT CONTROL BOX CABLES CABLES COV
SECTION 16: SPARE PARTS LIST Models: 80 (Oil on/off) Burner: MAX30 DESCRIPTION ROD ROD WAISTBAND ROD WAISTBAND ROD WAISTBAND BLAST TUBE BLAST TUBE GRATE NOZZLE HOLDER SUPPORT NOZZLE HOLDER DIFFUSER ELECTRODES FLANGE O'RING PIPE GASKET GASKET AIR DAMPER PIPE CAPACITOR PLUG WIELAND SOCKET WIELAND MOTOR COUPLING OIL PUMP HOSES IGN TRANSFORMER OIL VALVE OIL VALVE COIL COIL FAN FILTER OIL PUMP SUPPORT CONTROL BOX CABLES CABLES COVER RG P/N TC TL TC TL TC TL 6 UF AEG 7 200W DANFOSS SUNTEC DANFOSS SUNTEC DANFO
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 100 (Oil on/off) Burner: MAX35 DESCRIPTION ELECTRODES CAPACITOR HYDRAULIC SYSTEM COUPLING OIL PUMP ANTIJAMMING FILTER HOSES IGN TRANSFORMER OIL VALVE COIL COIL FUSE SUPPORT LAMP MAIN SWITCH HIGH-LOW FLAME SWITCH GASKET BURNER COVER COVER FAN NOZZLE HOLDER SUPPORT ROD ROD CABLES MOTOR BLAST TUBE BLAST TUBE NOZZLE HOLDER SUPPORT DIFFUSER COVER AIR INLET PIPE (2ND FLAME) PIPE HYDRAULIC SYSTEM PUMP PIPE FIRING HEAD HOSES
SECTION 16: SPARE PARTS LIST 16.
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL IGNITION CABLE COVER CONTROL BOX TL THERMOWAT E-BCU 91353003 90762013 90362001 Models: 40 and 50 (Oil high/low) Burner: MAX15 DESCRIPTION ROD ROD WAISTBAND ROD WAISTBAND ROD WAISTBAND BLAST TUBE BLAST TUBE GRATE COVER PROTECTION BOX NOZZLE HOLDER SUPPORT NOZZLE HOLDER DIFFUSER ELECTRODES CABLES IGNITION CABLE FLANGE O'RING PIPE GASKET GASKET AIR DAMPER PIPE CAPACITOR PLUG WIELAND PLUG WIELAND PLUG WIELAND SOCKET WIELAND HY
SECTION 16: SPARE PARTS LIST COVER 90752017 Models: 60, 70 and 80 (Oil High/low) Burner: MAX25 DESCRIPTION NOZZLE ROD ROD WAISTBAND BLAST TUBE BLAST TUBE GRATE COVER PROTECTION BOX NOZZLE HOLDER SUPPORT NOZZLE HOLDER DIFFUSER ELECTRODES FLANGE O'RING PIPE GASKET GASKET AIR DAMPER PIPE CAPACITOR PLUG WIELAND PLUG WIELAND PLUG WIELAND SOCKET WIELAND HYDRAULIC SYSTEM MOTOR COUPLING ANTIJAMMING FILTER HOSES IGN TRANSFORMER OIL VALVE OIL VALVE COIL COIL FAN PIPE (2ND FLAME) HYDRAULIC SYSTEM PIPE PIPE GASKET C
COMBAT® CABINET HEATERS INSTALLATION, COMMISSIONING, OPERATION AND SERVICE MANUAL Models: 100 Oil (high/low) Burner: MAX35 DESCRIPTION ELECTRODES CAPACITOR HYDRAULIC SYSTEM COUPLING OIL PUMP ANTIJAMMING FILTER HOSES IGN TRANSFORMER OIL VALVE COIL COIL FUSE SUPPORT LAMP MAIN SWITCH HIGH-LOW FLAME SWITCH GASKET BURNER COVER COVER FAN NOZZLE HOLDER SUPPORT ROD ROD CABLES MOTOR BLAST TUBE BLAST TUBE NOZZLE HOLDER SUPPORT DIFFUSER COVER AIR INLET PIPE (2ND FLAME) PIPE HYDRAULIC SYSTEM PUMP PIPE FIRING HEAD HOSE
SECTION 16: SPARE PARTS LIST 85 of 85
