Roberts Gorden Combat UHD-Series Installation, Operation & Service Manual

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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. 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.

Fire Hazard

Keep all flammable objects, liquids and vapors the minimum required clearances to combustibles away from heater.

Some objects will catch fire or explode when placed close to heater.

Failure to follow these instructions can result in death, injury or property damage.

WARNING

Installation must be done by a contractor qualified in the installation and service of gas-fired heating equipment or your gas 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 service technician with necessary information.

Combat

UHD-Series

Tubular Duct Furnace

(Standard Range)

Installation, Operation

& Service Manual

Models UHD[T][X][S][R]

150, 175, 200, 225 250, 300, 350, 400

Roberts-Gordon LLC

1250 William Street P. O . B o x 4 4 Buffalo, New York 14240-0044 Telephone: +1.716.852.4400 Fax: +1.716.852.0854 Toll Free: 800.828.7450

www.robertsgordon.com www.rg-inc.com

P/N 113001NA 11/13 Rev D

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AVERTISSEMENT

POUR VOTRE SECURITE

Si vous sentez une odeur de gaz:

1. Ouvrez les fenêtres.

2. N’essayez PAS d’allumer un appareil.

3. N’utilisez PAS d’interrupteurs électriques.

4. N’utilisez PAS de téléphone dans votre bâtiment.

5. Eteignez toute flamme nue.

6. Quittez le bâtiment.

7. Après avoir quitté le bâtiment, appelez immédiatement votre fournisseur local de gaz. Suivez les instructions du fournisseur de gaz.

8. Si vous ne pouvez pas joindre votre fournisseur de gaz, appelez le service d’incendie.

Risque d’incendie

Garder tous les objets, liquides ou vapeurs inflammables à la distance minimale de l’unité de chauffage requise avec les matériaux combustibles.

Certains objets prendront feu ou exploseront s’ils sont placés à proximité de l’unité de chauffage.

Le non respect de ces instructions peut entraîner la mort, des blessures corporelles ou des dommages matériels.

AVERTISSEMENT

L’installation doit être effectuée par un entrepreneur qualifié dans l'installation et l'entretien d'appareils de chauffage au gaz ou par votre fournisseur de gaz.

L’installation, le réglage, la modification, la réparation ou la maintenance inadapté peut entraîner la mort, des blessures ou des dommages matériels. Lire attentivement le manuel d'installation, d'utilisation et d'entretien avant d’installer ou de réparer cet équipement.

Combat

UHD-Series Appareil de

chauffage conduit à échangeur

tubulaire (Gamme standard)

Manuel d’installation,

d’operation, et de service

Modèles UHD[T][X][S][R]

150, 175, 200, 225

250, 300, 350, 400

Installateur

Veuillez prendre le temps de lire et de comprendre ces

instructions avant toute installation. L’installateur doit

donner un exemplaire de ce manuel au propriétaire.

Propriétaire

Garder ce manuel dans un endroit sûr pour fournir les

informations nécessaires au personnel d’entretien.

Roberts-Gordon LLC

1250 William Street P. O . B o x 4 4 Buffalo, New York 14240-0044 Téléphone: +1.716.852.4400 Fax: +1.716.852.0854 Numéro sans fraís: 800.828.7450

www.robertsgordon.com www.rg-inc.com

P/N 113001 F C 11 / 1 3 Rev D

Page 4

Page 5

Roberts-Gordon LLC

All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Roberts-Gordon LLC.

TABLE OF CONTENTS

SECTION 1: Heater Safety......................................................1

1.1 Manpower Requirements .............................................1

1.2 Safety Labels and Their Placement .............................1

1.3 California Proposition 65 ..............................................1

SECTION 2: Installer Responsibility .....................................5

2.1 Wall Tag .......................................................................5

2.2 Corrosive Chemicals....................................................5

2.3 National Standards and Applicable Codes .................. 5

SECTION 3: Critical Considerations .....................................6

3.1 Basic Information.........................................................6

3.2 Manufactured Units......................................................6

3.3 Location and Suspension ............................................6

3.4 Minimum Required Installation Clearances ................. 6

3.5 Ventilation ....................................................................6

3.6 Gas Supply ..................................................................6

3.7 Electrical Supply ..........................................................6

3.8 Vent.............................................................................. 6

SECTION 4: Clearances to Combustibles............................. 7

4.1 Required Clearances to Combustibles......................... 7

4.2 Clearances to Combustibles ........................................7

SECTION 5: National Standards and Applicable Codes .....8

5.1 Gas Codes...................................................................8

5.2 Aircraft Hangars ........................................................... 8

5.3 Parking Structures and Repair Garages......................8

5.4 Electrical ......................................................................8

5.5 Venting.........................................................................8

5.6 High Altitude ................................................................9

SECTION 6: Duct Heater Installation................................... 10

6.1 General...................................................................... 10

6.2 Suspension................................................................ 11

SECTION 7: Venting.............................................................. 12

7. 1 Venting .......................................................................12

7. 2 Vent Installation..........................................................12

7.3 Horizontal Venting ...................................................... 13

7. 4 Vertical Venting........................................................... 13

7.5 Maximum Vent Lengths Table ................................... 13

7. 6 Vent Material............................................................... 13

SECTION 8: Air Supply......................................................... 18

8.1 Separated Comb

8.2 Building Ventilation ....................................................18

8.3 Outside Combustion Air Supply................................. 18

SECTION 9: Gas Piping........................................................ 19

9.1 Connections............................................................... 19

SECTION 10: Wiring..............................................................21

10.1 Positioning Thermostats ..........................................21

10.2 Low Voltage Thermostat with One Heater for

Models UHD[T][X][S][R] 150-250 .............................. 21

10.3 Low Voltage Thermostat with One Heater for

Models UHD[X][S][R] 300-400 ..................................22

ustion Installation............................ 18

10.4 UHD[X][S][R] Series Internal Wiring Diagram for

Single Stage Gas Valves ...........................................23

10.5 UHD[X][S][R] Series Ladder Wiring Diagram for

Single Stage Gas Valves ...........................................24

10.6 UHD[T][X][S][R] Series Internal Wiring Diagram for

Two Stage Gas Valves ...............................................25

10.7 UHD[T][X][S][R] Series Ladder Wiring Diagram for

Two Stage Gas Valves ...............................................26

10.8 Electrical Connection to the Heater..........................27

SECTION 11: Operation and Maintenance ..........................28

11.1 Pre-Start-Up Checks .................................................28

11.2 Begin Start-Up ..........................................................28

11.3 Pressure Switch ........................................................31

11.4 External Controls ......................................................31

11.5 Complete Start-Up ....................................................31

11.6 Instruction to the User...............................................31

SECTION 12: User Instructions............................................32

12.1 Heater Operation......................................................32

12.2 Lighting Instructions .................................................32

12.3 Simple Troubleshooting............................................32

SECTION 13: Servicing.........................................................33

13.1 Servicing Instructions...............................................33

13.2 Burner Maintenance.................................................33

13.3 Heat Exchanger Maintenance..................................33

13.4 Gas Valve Maintenance ...........................................34

13.5 Flue Blower..............................................................34

13.6 Venting and Air Intake Pipe......................................34

13.7 Maintenance Checklist .............................................34

SECTION 14: Troubleshooting .............................................37

14.1 General ....................................................................38

14.2 Troubleshooting For Automatic Ignition Burner

Systems...................................................................39

14.3 Troubleshooting for Flame Supervision System .......40

14.4 Troubleshooting for Gas Valves................................41

14.5 Troubleshooting for Flue Blower...............................41

SECTION 15: Replacement Parts.........................................42

15.1 Gas Valve.................................................................42

15.2 Burner Compartment for Models UHA[T][X][S][R]

150-250......................................................................43

15.3 Burner Compartment for Models UHD[X][S][R]

300-400 .....................................................................45

15.4 Ignition Electrode and Flame Probe for Models

UHD[T][X][S][R] 150-250 ...........................................46

15.5 Ignition Electrode and Flame Probe for Models

UHD[X][S][R] 300-400 ...............................................47

15.6 Heat Exchanger .......................................................48

15.7 Flue Blower for Models UHD[T][X][S][R] 150-175 ....48

15.8 Flue Blower for Models UHD[T][X][S][R] 200-250 ...49

15.9 Flue Blower for Models UHD[X][S][R] 300-400 ........50

Printed in U.S.A.

Page 6

15.10 Pressure Switch ..................................................... 51

15.11 Ignition Control....................................................... 51

15.12 Limit Switches........................................................ 51

SECTION 16: Specifications ................................................ 52

16.1 Dimension Data for Models UHD[T][X][S][R]

150-250.................................................................... 52

16.2 General Technical Data Table .................................. 53

16.3 Technical Data Table................................................ 53

16.4 Dimension Data for Models UHD[X][S][R]300-400 .. 54

16.5 General Technical Data Table .................................. 55

16.6 Technical Data Table................................................ 55

SECTION 17: The ROBERTS GORDON

UHD-Series

Warranty ......................................................... 57

Page 7

TABLE OF FIGURES

Figure 1: UHD[T][X][S][R] 150-175 Label Placement................ 2

Figure 2: UHD[T][X][S][R] 200-250 Label Placement ............... 3

Figure 3: UHD[X][S][R] 300 – 400 Label Placement................. 4

Figure 4: Clearances to Combustibles ......................................7

Figure 5: Air Flow Direction ..................................................... 10

Figure 6: Suspension Methods ............................................... 11

Figure 7: Vent and Roof Detail................................................ 13

Figure 8: Standard Vented Heater - Vertical and Horizontal

Vent Termination......................................................14

Figure 9: Standard Vented Heater - Common Vertical Vent

Termination.............................................................. 15

Figure 10: Separated Combustion Heater - Vertical and

Horizontal Vent Termination..................................... 16

Figure 11: Concentric Vent Box...............................................16

Figure 12: Concentric Vertical and Horizontal Vent

Termination - Separated Combustion Heater .......... 17

Figure 13: Gas Connection ..................................................... 20

Figure 14: Automatic Burner Control Sequence......................29

Figure 15: Single Stage Gas V

150 – 400.................................................................29

Figure 16: Two Stage Gas Valve for Models UHD[T][X][S][R]

150 - 250 .................................................................30

Figure 17: LED Diagnostic Codes...........................................32

alve for Models UHD[X][S][R]

There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Roberts-Gordon LLC is not sponsored by or affiliated with any of the trademark or registered trademark owners, and makes no representations about them, their owners, their products or services.

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SECTION 1: HEATER SAFETY

Yo ur 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, at a minimum, annual inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Read this manual carefully before installation, operation or service of this equipment. Heaters are not approved for residential installation. 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 1: HEATER SAFETY

1.2 Safety Labels and Their Placement

Product safety signs or labels should be replaced by the product user when they are no longer legible. Please contact Roberts-Gordon LLC or your ROBERTS GORDON

independent distributor to obtain replacement signs or labels. See Page 2, Figure 1 through Page 4, Figure 3.

1.3 California Proposition 65

In accordance with California Proposition 65 requirements, a warning label must be placed in a highly visible location on the outside of the equipment (i.e. near equipment's serial plate). See label placement drawing on Page 2, Figure 1 through Page 4, Figure 3 for label location. Avoid placing label on areas with extreme heat, cold, corrosive chemicals or other elements. To order additional labels, please contact Roberts-Gordon LLC or your ROBERTS GORDON

independent

distributor.

Protective gear is to be worn during installation, operation and service. Thin sheet metal parts, including the various venting components, have sharp edges. To prevent injury, the use of work gloves is recommended.

Before installation, check that the local distribution conditions, nature of gas and pressure and adjustment of the appliance are compatible.

This heater must be applied and operated under the general concepts of reasonable use and installed using the best building practices. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. For additional copies of the Installation, Operation and Service Manual, please contact RobertsGordon LLC.

1. 1 M an p o w e r Re quirements

To prevent personal injury and damage to the heater, two persons will be required for installation.

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UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Description Part Number

Logo Label 91040030

Vent Length Label 91039505 Vent to Outdoors Label 91010427

Warning Label 91010429 Rating Plate Label 91039802 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label* 91010426 Proposition 65 Label 91070015

* For separated combustion units only

Figure 1: UHD[T][X][S][R] 150-175 Label Placement

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Figure 2: UHD[T][X][S][R] 200-250 Label Placement

Description Part Number

Logo Label 91040030

Vent Length Label 91039505 Vent to Outdoors Label 91010427

* For separated combustion units only

SECTION 1: HEATER SAFETY

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UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

* For separated combustion units only

Description Part Number

Logo Label 91040030

Vent Length Label 91039505 Vent to Outdoors Label 91010427

Figure 3: UHD[X][S][R] 300 – 400 Label Placement

VENT TO OUTDOORS DONNER VENT A DEHORS

Printed in U.S.A. / Imprimé aux Etats Unis

P/N 91010427

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SECTION 2: INSTALLER RESPONSIBILITY

CAUTION

Product Damage Hazard

Do not use equipment in area containing corrosive chemicals.

Refer to appropriate Material Safety Data Sheets (MSDS).

Failure to follow these instructions can result in product damage.

The installer is responsible for the following:

• To install the heater, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon LLC recommends the installer contact a Local Building Inspector or Fire Marshal for guidance.

• To use the information given in a layout drawing and in the manual together with the cited codes and regulations to perform the installation.

• To install the heater in accordance with the clearances to combustibles.

• To furnish all needed materials not supplied as standard equipment.

• To plan location of supports, vents and air intakes.

• To provide access for servicing.

• To provide the owner with a copy of this Installation, Operation and Service Manual.

• To never use heater as support for a ladder or other access equipment and never hang or suspend anything from heater.

• To ensure there is adequate air circulation around the heater and to supply air for combustion, ventilation and distribution in accordance with local codes.

• To provide a method that ensures that the air flow through the heat exchanger is within the acceptable range indicated on the serial plate prior to energizing the heater, and that such air flow continues at least 90 seconds after the heater is de-energized.

• To ensure the heater is placed in an approved application.

2.1 Wall Tag

A laminated wall tag is included with the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles. Affix the tag by peeling off the backing of the adhesive strips on the rear surface and position the tag on a wall near the heater.

A copy of the wall tag (P/N 91039831) is illustrated on the back cover.

Know your model number and installed configuration. Model number and installed configuration are found on the heater serial plate and throughout the Installation, Operation and Service Manual.

SECTION 2: INSTALLER RESPONSIBILITY

2.2 Corrosive Chemicals

Roberts-Gordon LLC 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 in the premises.

* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the life span of the heater components will be greatly reduced. An outside air supply must be provided to the burners whenever the presence of these compounds is suspected. 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 the applicable standards 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. See Page 8, Section 5.

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UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 3: CRITICAL CONSIDERATIONS

3.1 Basic Information

UHD[T][X][S][R] heaters have automatic ignition burners for ON/OFF or HIGH/LOW operation only.

• May be mounted on a shelf of non-combustible material.

• May be suspended from above (See Page 11, Section 6.2) or from wall brackets of sufficient

3.2 Manufactured Units

Gas-fired, power-vented duct furnace with tubular heat exchanger. Units shall have a minimum of 82% thermal efficiency. The standard unit shall consist of a non-separated combustion design with an aluminized heat exchanger and a single stage gas valve. Design and heat exchanger alternatives shall be offered as follows:

• Separated Combustion: [S] For Models 150-250,

strength to support the heater as listed in the Technical Data Table on Page 53, Section 16.2 and Page 55, Section 16.5.

• Drop rods must be a minim mild steel. Four suspension points (3/8" nuts) are located on top of the heater.

•Must be installed in a manner which allows access to all serviceable components.

a separated combustion unit shall consist of a sealed hinged enclosure. Combustion air inlet flange on rear of heater

allows for combustion air from outside heated space to be attached. For Models 300-400, a separated combustion

3.4 Minimum Required Installation Clearances

Clearances around the heater and vent must be as indicated on Page 7, Figure 4 and Page 12, Section 7 to ensure access for servicing and correct operation.

unit shall feature an enclosed, sealed burner box. A piece of flexible air duct connects this burner box to a flange on the cabinet. Combustion air shall be ducted from outside the heated space, with the ductwork connecting to the unit with the use of the flange.

• Stainless Steel Heat Exchanger: [X] A stainless

3.5 Ventilation

It is important to ensure that there is adequate air space around the heater to supply air for combustion, ventilation and distribution in accordance with local and national code on Page

12, Section 7. steel heat exchanger unit shall consist of heat exchanger tubes, heat exchanger tube supports and heat exchanger tube plate produced of 409 stainless steel.

Air inlet temperatures below 40° F (4.4° C) are not recommended.

•Two Stage Gas Valve: [T] A two stage gas valve

3.6 Gas Supply

It is important that the gas supply pipe is sized

correctly to provide the inlet pressure as stated on

the heater data plate. The gas supply pipe and

electrical connections must not support any of the

heater's weight. See Page 19, Section 9. shall allow heater to function in HIGH/LOW

operation.

• Approved for Installation Downstream of a Refrigeration System: [R] Installation allows for unit to be installed downstream of a refrigeration system. Unit design shall include a 409 stainless

3.7 Electrical Supply

A permanent 120 V / 1 Ø / 60 Hz electrical supply is required for the main electrical power. The heater also requires suitable controls listed on Page 21, Section 10.

steel package. Stainless steel package includes heat exchanger, tube supports and drip pan.

3.8 Vent

Choose heater orientation to allo

3.3 Location and Suspension

All models:

•Must be installed indoors.

•Must be installed on the positive pressure side of

location of the vent. Each heater must be fitted with a correctly sized sealed vent system.

If vented horizontally, no other appliance may be connected to the vent. See Page 12, Section 7.

the air circulation blower.

•Must be installed in a level position with horizontal discharge.

um of 3/8" diameter

w for proper

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Page 15

SECTION 4: CLEARANCES TO COMBUSTIBLES

WARNING

Fire Hazard

Keep all flammable objects, liquids and vapors the required clearances to combustibles away from heater.

Some objects can catch fire or explode when placed close to heater.

Failure to follow these instructions can result in death, injury or property damage.

Clearance to Vent: 2" (5 cm)

*31" (79 cm) minimum is necessary for servicing.

4.1 Required Clearances to Combustibles

SECTION 4: CLEARANCES TO COMBUSTIBLES

of exposure to combustible airborne materials or vapors.

4.2 Clearances to Combustibles

Clearances must be as indicated on Page 7, Figure

4. If clearances to combustibles are not indicated,

then installation clearances apply. All distances are minimum clearance requirements for service access, air flow and safety.

Figure 4: Clearances to Combustibles

(15 cm)

Clearances are the required distances that combustible objects must be away from the heater to prevent a fire hazard. Combustibles are materials that may catch on fire and include common items such as wood, paper, rubber, fabric, etc. Maintain clearances to combustibles at all times for safety. Clearances for all heater models are located on the serial plate, wall tag and throughout the manual. Check the clearances on the serial plate to make sure the product is suitable for your application and the clearances are maintained. Read and follow the safety guidelines below:

• Keep gasoline or other combustible material including flammable objects, liquids, dust or vapors away from this heater or any other appliance.

• Do not spray aerosols in the vicinity of this heater.

• The stated clearances to combustibles represents a surface temperature of 90° F (50° C) above room temperature. Building materials with a low heat tolerance (such as plastics, vinyl siding, canvas, tri-ply, etc.) may be subject to degradation at lower temperatu is the installer's and owner's responsibility to assure that adjacent materials are protected from degradation.

• Maintain clearances from heat sensitive equipment and work stations.

• Consult local Fire Marshal, Fire Insurance Carrier or other authorities for approval of proposed installation when there is a possibility

res. It

(15 cm)

31"*

(79 cm)

(15 cm)

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Page 16

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 5: NATIONAL STANDARDS AND APPLICABLE CODES

5.1 Gas Codes

The type of gas appearing on the serial plate must be the type of gas used. Installation must comply with national and local codes and requirements of the local gas company.

United States: Refer to NFPA 54/ANSI Z223.1 latest revision, National Fuel Gas Code.

Canada: Refer to CSA B149.1 Natural Gas and Propane Installation Code.

5.2 Aircraft Hangars

Installation in aircraft hangars must be in accordance with the following codes:

United States: Refer to Standard for Aircraft Hangars, NFPA 409 - latest revision.

Canada: Refer to Standard CSA B149.1 Natural Gas and Propane Installation Code.

• In aircraft storage and servicing areas, heaters shall be installed at least 10' (3 m) above the upper surface of wings or of engine enclosures of the highest aircraft which may be housed in the hangar. The measurement shall be made from the wing or engine enclosure (whichever is higher from the floor) to the bottom of the heater.

• In shops, offices and other sections of aircraft hangars communicating with aircraft storage or servicing areas, heaters shall be installed not less than 8' (2.4 m) above the floor.

• Suspended or elevated heaters shall be so located in all spaces of aircraft hangars that they shall not be subject to injury by aircraft, cranes, movable scaffolding or other objects. Provisions shall be made to assure accessibility to suspended heaters for recurrent maintenance purposes.

5.3 Parking Structures and Repair Garages

Installation in garages must be in accordance with the following codes:

United States: Standard for Parking Structures NFPA 88A - latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages, NFPA 30A - latest revision. Canada: Refer to CSA B149.1 Natural Gas and Propane Installation Code.

• In accordance with the Standard for Parking Structures NFPA 88A, heaters must be located a minimum of 18" (50 cm) below the floorceiling assembly or 18" (50 cm) above the floor.

• In accordance with the Code for Motor Fuel Dispensing Facilities and Repair Garages, NFPA 30A - latest revision, heaters must not be installed less than 8' (2.4 m) above the floor.

5.4 Electrical

The heater must be electrically grounded in accordance with the following codes:

United States: Refer to National Electrical

Code

, NFPA 70 - latest revision. Wiring must

conform to the most current National Electrical

Code

, local ordinances and any special

diagrams furnished.

Canada: Refer to Canadian Electrical Code, CSA C22.1 Part 1 - latest revision.

5.5 Venting

The venting must be installed in accordance with the requirements within this manual and

the following codes:

United States: Refer to NFPA 54/ANSI Z223.1 latest revision, National Fuel Gas Code.

Canada: Refer to CSA B149.1 Natural Gas and Propane Installation Code.

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5.6 High Altitude

These heaters are approved (without modifications) for installations up to 2000' (610 m) in US and Canada. Heaters installed above 2000' (610 m) must be de-rated. For installations above 2000' (610 m) in US, consult factory for information on burner de-rating. For installations from 2000' (610 m) to 4500' (1370m) in Canada, high altitude conversion kits are available. Heaters installed over 4500' (1370 m) in Canada are not approved and must be approved by the local or provincial authority.

SECTION 5: NATIONAL STANDARDS AND APPLICABLE CODES

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Page 18

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 6: DUCT HEATER INSTALLATION

6.1 General

To connect the inlet and outlet ducts to the heater, Duct-Mate or similar flanges may be slid over the duct connector flanges supplied on the unit and secured with screws. The connection to the duct then can be made using the Duct-Mate clips. The ducts must have removable access panels upstream and downstream of the heater. These panels must be of appropriate size and placement so that smoke or reflected light could be observed to indicate the presence of leaks in the heat exchanger. Covers for these openings should be sealed to prevent leakage.

Any transition into the inlet of the heater should be smooth, with a taper of no more than 15 degrees. If elbows are required, they should be of either broad radius or fitted with properly designed turning vanes. Consult a professional to ensure turning vanes are properly designed.

The heater must be installed on the positive pressure side of the circulating air blower. Air flow through the heater must be as shown on Page 10, Figure 5 and may not be reversed. The air flow

must be adjusted such that it is within the acceptable range shown on Page 10, Section 6.1.2.

The minimum inlet duct lengths shown on Page 10, Section 6.1.1 must be observed. Pressure drop through the heat exchanger at various air flows is shown on Page 10, Section 6.1.2.

Figure 5: Air Flow Direction

6.1.1 Minimum Inlet Duct Length

Model Duct Length Duct Size (W X H)

UHD[T][X][S][R] 150-175 52" (132 cm) 28" x 24" (71 cm x 60 cm) UHD[T][X][S][R] 200-250 60" (162 cm) 28" x 32 1/2" (71 cm x 83 cm) UHD[X][S][R] 300-400 75" (190 cm) 35" x 40 1/2" (89 cm x 82 cm)

6.1.2 Temperature Rise and Pressure Drop Ranges

UHD[T][X][S][R] 150 UHD[T][X][S][R] 175 UHD[T][X][S][R] 200 UHD[T][X][S][R] 225

Airflow

(CFM)

1,360 83 0.02 1,400 95 0.03 2,050 73 0.025 2,100 80 0.035 1,950 58 0.035 2,180 62 0.06 2,600 58 0.035 2,800 61 0.052 2,800 41 0.057 3,244 42 0.10 3,600 42 0.056 4,600 37 0.110 3,700 31 0.083 4,370 31 0.15 5,500 28 0.100 6,230 27 0.167 4,700 24 0.12 5,160 27 0.19 6,570 23.5 0.129 7,400 23 0.214 5,800 20 0.16 6,850 20 0.29 7,750 20 0.163 8,300 20 0.253

Airflow

(CFM)

2,350 80 0.05 2,700 86 0.02 3,120 86 0.03 3,420 86 0.04 3,000 63 0.07 4,735 50 0.06 4,880 56 0.07 5,200 57 0.08 4,400 43 0.13 6,813 35 0.12 6,612 41 0.123 6,700 45 0.13 5,900 32 0.19 8,000 30 0.17 9,140 30 0.23 8,850 34 0.21

8,850 22 0.35 10,200 23 0.27 13,600 22 0.48 14,200 22 0.53

Temperature

Rise (°F)

UHD[T][X][S][R] 250 UHD[X][S][R] 300 UHD[X][S][R] 350 UHD[X][S][R] 400

Temperature

Rise (°F)

7,625 25 0.28 9,300 26 0.22 10,500 26 0.30 11,600 26 0.36

Pressure

Drop

(in wc)

Pressure

Drop

(in wc)

Airflow

(CFM)

Airflow

(CFM)

Temperature

Rise (°F)

Temperature

Rise (°F)

Pressure

Drop

(in wc)

Pressure

Drop

(in wc)

Airflow

(CFM)

Airflow

(CFM)

Temperature

Rise (°F)

Temperature

Rise (°F)

Pressure

Drop

(in wc)

Pressure

Drop

(in wc)

Airflow

(CFM)

Airflow

(CFM)

Temperature

Rise (°F)

Temperature

Rise (°F)

Pressure

Drop

(in wc)

Drop

(in wc)

10 of 57

Page 19

SECTION 6: DUCT HEATER INSTALLATION

WARNING

Crush Hazard

Use 3/8" threaded rod minimum.

Failure to follow these instructions can result in death, injury or property damage.

Nut

Washer

Riv

Nut

Ensure all 3/8"-16 threaded suspension hardware is torqued to a minimum of 19 ft lbs. (25.8Nm)

Support Points (for use in handling)

3/8"-16 Threaded Rod

Cone Point

Set Pin

Window

Clamp

Unistrut

3/8"-16

Threaded

Rod

Washer

Nut

Channel Nut

NOTE:

Four suspension points located on top of heater. Duct supports not shown. Duct supports and duct are not provided by manufacturer.

6.2 Suspension

For typical suspension, See Page 11, Figure 6. When handling or supporting the heater from below, ensure that the weight is taken at the support points.

Figure 6: Suspension Methods

The gas or electrical supply lines must not be used to support the heater.

Do not locate the gas or electrical supply lines directly over the path of the flue products from the heater.

The heater must be installed in a location that is readily accessible for servicing.

The heater must be installed in accordance with clearances to combustibles as indicated on the serial plate, wall tag and throughout the manual. See Page 7, Section 4.

11 of 57

Page 20

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

WARNING

Carbon Monoxide Hazard

Heaters must be vented outdoors.

Heaters must be installed according to the installation manual.

Failure to follow these instructions can result in death or injury.

SECTION 7: VENTING

7. 1 V e n t i n g

This heater must be vented in accordance with the rules contained in this manual and with the following national codes and any state, provincial or local codes which may apply: United States: Refer to NFPA 54/ANSI Z223.1 - latest revision, National Fuel Gas Code; Canada: Refer to CSA B149.1 Natural Gas and Propane Installation Code. Any portion of vent pipe passing through a combustible wall must have a listed thimble to conform with the above codes.

The bottom of the vent or air intake terminal shall not be located less than 1' (.3 m) above grade level.

The vent shall not terminate less than 7' (2.1 m) above grade where located adjacent to public

walkways. Vent terminal must be installed at a height sufficient

to prevent blockage by snow and building materials protected from degradation by flue gasses.

Vent terminal must be beyond any combustible overhang.

Secure all joints with corrosion resistant #8 x 3/8" sheet metal screws.

For single wall venting, pressure sensitive aluminum tape or silicone sealant must be used to seal all joints.

Aluminum tape shall have a minimum temperature rating of 400° F (204° C) and meet SMACNA AFTS100-73 standards. High temperature silicone sealant must have a minimum temperature rating of 480° F (250° C).

7.1.1 United States Requirements

Vent must terminate at least 3' (.9 m) above any forced air inlet located within 10' (3.1 m).

Vent must terminate at least 4' (1.2 m) below, 4' (1.2 m) horizontally from, or 1' (.3 m) above any door, operable window, or gravity air inlet into any

12 of 57

building. NFPA 54/ANSI Z223.1 - latest revision, National

Fuel Gas Code specifies a 4' (1.2 m) horizontal vent terminal clearance from gas and electric meters, regulators and relief equipment.

7. 1. 2 C a n a d i a n Re quirements

The vent shall not terminate within 6' (1.8 m) of a mechanical air supply inlet to any building.

The vent shall not terminate within 3' (.9 m) of a window or door that can be opened in any building, any non-mechanical air supply inlet to any building, or of the combustion air inlet of any other appliance.

7.2 Vent Installation

Maintain clearances to combustibles at all times for safety. Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazard. See Page 7

4. For vented units, the vent must terminate outside of the building. Vents must be fully sealed and correctly sized for the model. If the vent passes through a wall or ceiling of combustible material, it must be enclosed by a listed thimble and be separated from the thimble by at least a 2" (5 cm) air gap.

For separated combustion models, vents and air intakes must be a fully sealed system and correctly sized for the model. Vent should be assembled as detailed on Page 13, Figure 7 through Page 17, Figure 12.

The joints between the vent terminal and the roof or wall must be properly sealed.

Vents and air intakes must be adequately supported so that the heater does not bear the weight of the pipes.

For vent termination See Page 13, Figure 7 through Page 17, Figure 12.

7.2.1 Standard Vented Heaters (Models UHD[T][X][R] 150 - 250 and Models UHD[X][R] 300 - 400)

The vent must be fitted with a low resistance terminal. See Page 13, Figure 7 through Page 15, Figure 9. Standard vented heaters do not allow outdoor air intake for combustion air.

7.2.2 Separated Combustion Heaters (Models UHD[T][X]S[R] 150 - 250 and Models UHD[X]S[R] 300 - 400)

The heaters are designed to be installed as separated combustion heaters. The vent and air intake are ru

n as separate pipes to the wall or roof

, Section

Page 21

SECTION 7: VENTING

Roof

Vent

Terminal

Listed Thimble

Flashing

or Rain Collar

Vent

2" (5 cm) Air Gap

to Combustible

Material

terminals. See Page 16, Figure 10. As an option, the vent and air intake are run as separate pipes to a concentric vent box and a concentric vent/air intake pipe penetrates the wall or roof. See Page 16, Figure 11 and Page 17, Figure 12.

For separated combustion installation, the vent and air intake must be fitted with an individual and correctly sized sealed system and the vent and air intake must terminate at approved wall and roof terminals.

Separated combustion units may not be common vented.

7.3 Horizontal Venting

Horizontally vented heaters must be individually vented, no common venting.

Vent pipe must be sloped ¼" (.6 cm) downward for every 1' (.3 m).

In noncombustible walls only, vent terminal (P/N 02537801-1P) may be used.

For 4'' (10 cm) vents in either combustible or noncombustible walls, use vent terminal (P/N

90502100) or equivalent insulated vent terminal. Follow the manufacturer's instructions for proper installation.

Instead of an insulated vent terminal, a listed thimble with 2" (5 cm) air gap may be used with a 4" (10 cm) vent cap (P/N 90502102).

7.6 Vent Material

Vent material may be single wall 26 ga. (minimum) galvanized steel or equal thickness stainless steel. Completely seal all joints, refer to Page 12, Section

7.2. If penetrating a combustible wall or roof, a listed thimble with 2" (5 cm) clearance must be used. Where local codes permit, a single section of type B-1 vent material may be used at the roof or wall penetration instead of a thimble. Ensure vent manufacturer's clearance from vent material is maintained. Seal annular space of the type B-1 vent as well as all joints in the remaining vent.

Figure 7: Vent and Roof Detail

7.4 Vertical Ventin

Vertically vented standard vented heaters can be common vented (up to four heaters).

For 4'' (10 cm) common vent, an approved vent cap (P/N 90502102) must be used.

For 6'' (15 cm) common vent, an approved vent cap (P/N 90502103) must be used.

For common vertical venting of more than two heaters, See Page 15, Figure 9.

A vent shall not extend less than 2' (.6 m) above the highest point where it passes through a flat roof of a building.

7.5 Maximum Vent Lengths Table

Model UHD[T][X][S][R] 150 - 250

Model UHD[X][S][R] 300 - 400

30 ft (9.1 m) 1

25 ft (7.6 m) 2 20 ft (6.1 m) 3 15 ft (4.5 m) 4 10 ft (3.0 m) 5

# of Elbows

13 of 57

Page 22

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Model Vent Diameter Part Number

UHD[T][X][R] 150 - 250 UHD[X][R] 300 - 400

4" (10 cm) 90502102

Figure 8: Standard Vented Heater - Vertical and Horizontal Vent Termination

14 of 57

Page 23

Figure 9: Standard Vented Heater - Common Vertical Vent Termination

Roof

2'(.6 m)

Minimum

Type "B" vent cap (7" [18 cm] or 8" [20 cm]) may be used. (These are not available from the manufacurer.)

Roof

Flashing

Approved

Thimble

(If Applicable)

Type "B" Vent Pipe

4" (10 cm)

Single Wall Pipe

4" (10 cm)

Single Wall Pipe

"D" Area must equal sum

of open area of

individual vents.

"D"

Single Wall Pipe

The last section of vent pipe passing through the roof or wall may be Type "B" vent pipe. All other vent materials in the building must be single wall vent pipe.

TOP VIEW

SIDE VIEW

SECTION 7: VENTING

Requirements:

• Maximum of four heaters can be commonly vented through the roof.

• Heaters must be of the same BTU output.

• Heaters must be controlled by a common thermostat.

• Connections to a common stack must be positioned to avoid direct opposition between streams of combustion gases.

15 of 57

Page 24

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Model **Vent Diameter Part Number

UHD[T][X]S[R] 150 - 250 4" (10 cm) 90502102 UHD[X]S[R] 300 - 400 4" (10 cm) 90502102

Model *Air Intake Diameter Part Number

UHD[T][X]S[R] 150 - 250 4" (10 cm) 90502102 UHD[X]S[R] 300 - 400 5" (13 cm) 90502105

Figure 10: Separated Combustion Heater - Vertical and Horizontal Vent Termination

Figure 11: Concentric Vent Box

16 of 57

Page 25

SECTION 7: VENTING

Vent**

Air Intake*

Concentric Vent Box

Vertical

Option

Horizontal Option

Concentric Vent Box

Vent**

Combustion Air Terminal

12" (31 cm) Minimum from roof to combustion air terminal

Vent Terminal with Baffle Plate

Flashing (By Others)

4" (10 cm)

Type B-1 Vent

Storm Collar (By Others) (Attach with 3 sheet metal screws.)

UHDS 150-250: 6"

(15 cm)

Diameter Single Wall UHDS 300-400: 8"

(20 cm)

Diameter Single Wall

Air Intake*

6" (16 cm)

Minimum

12" (31 cm)

Maximum

Combustion Air Terminal

Vent Terminal with Baffle Plate

(10 cm)

Type

B-1

Vent

Storm Collar (By Others) (Attach with 3 sheet metal screws.)

6" (16 cm) Minimum 12" (31 cm) Maximum

10' (3 m)

Maximum

NOTE: Vent supports not shown. Duct supports not shown. Duct and vent supports not provided by the manufacturer.

12" (31 cm) Minimum from wall to combustion air terminal

Description Part Number Qty. Concentric Vent Kit (150 - 250) UHVK1

Concentric Vent Box Top & Side Assembly 90504113 1 Concentric Vent Box Bottom Assembly 90504112 1 Screw #6 x 3/8 Self Drilling 91119100 14 4" (10 cm) Vent Terminal with Baffle Plate 90502102R 1 6" (15 cm) Combustion Air Terminal 90502103 1

Description Part Number Qty. Concentric Vent Kit (300 - 400) UHVK2

Concentric Vent Box Top & Side Assembly 90504013 1 Concentric Vent Box Bottom Assembly 90504012 1 Screw #6 x 3/8 Self Drilling 91119100 14 4" (10 cm) Vent Terminal with Baffle Plate 90502102R 1 8" (20 cm) Combustion Air Terminal 90502104 1

Model **Vent Diameter

UHD[T][X]S[R] 150 - 250 4" (10 cm) UHD[X]S[R] 300 - 400 4" (10 cm)

Model *Air Intake Diameter

UHD[T][X]S[R] 150 - 250 4" (10 cm) UHD[X]S[R] 300 - 400 5" (13 cm)

Figure 12: Concentric Vertical and Horizontal Vent Termination - Separated Combustion Heater

17 of 57

Page 26

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

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.

SECTION 8: AIR SUPPLY

8.1 Separated Combustion Installation

When installed as a separated combustion heater (UHD[T][X]S[R]), the air for combustion is drawn in from outside the building.

8.2 Building Ventilation

Where ventilation is required, air must be taken from an outside point where it is not likely to be contaminated or obstructed.

8.3 Outside Combustion Air Supply

If outside combustion air supply is required, separated combustion model (UHD[T][X]S[R]) heaters must be used.

Caution: If the building has a slight negative pressure or corrosive contaminants such as halogenated hydrocarbons are present in the air, an outside combustion air supply to the heater is required. Seal all combustion air pipe joints. For models 300-400, the flexible air duct may be insulated to prevent condensation on the outer surface. The outside air terminal must not be more than 1' (31 cm) above the vent terminal.

8.3.1 Length Requirements

the constraints listed on Page 13, Section 7.5.

18 of 57

Page 27

SECTION 9: GAS PIPING

WARNING

Explosion Hazard

Leak test all components of gas piping before operation.

Gas can leak if piping is not installed properly.

Do not high pressure test gas piping with heater connected.

Failure to follow these instructions can result in death, injury or property damage.

Fire Hazard

Connect gas supply according to Figure 13.

Do not use gas supply pipe and electrical connections to support heater’s weight.

Gas can leak if not installed properly.

Failure to follow these instructions can result in death, injury or property damage.

A gas meter is connected to the service pipe by the gas supply company. An 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. Pipes of smaller size than the heater inlet gas connection should not be used.

Gas lines must meet applicable codes: United States: Flexible stainless steel gas hose

(US models) is certified per the standard for connectors for gas appliances. ANSI Z21.21/CSA

6.10 – latest revision.

SECTION 9: GAS PIPING

Canada: Rubber type 1 gas hose (Canadian

models) is certified as being in compliance with the standard for elastomeric composite hose and hose couplings for conducting propane and natural gas, CAN/CGA 8.1 – latest revision.

9.1 Connections

Connect the heater to the gas supply ensuring that the final connections are as follows:

•Gas supply pipe work is run in medium or heavy gauge tubing in compliance with local and national codes.

• Meter and service must be large enough to handle all the burners being installed plus any other connected load. The gas pipe which feeds the system must be large enough to supply the required gas 1/2" wc. When gas piping is not included in the layout drawing, contact the local gas supplier.

• An isolating valve and union connection should be used and fitted into the supply adjacent to the heater.

•For suspended heaters, an approved metal flexible connection between the isolating valve and the heater may be used. To reduce

pressure loss, use one pipe size larger than the heater gas connection.

IMPORTANT - The complete installation must be

purged and tested for gas soundness in accordance with local and national codes.

Caution: Do not high pressure (in excess of 1/2 psi [14" wc]) test the gas piping with the burner connected. Close manual shut-off valve during any pressure testing equal to or less than 1/2 psi (14" wc).

Check the pipe and tubing ends for leaks before placing heating equipment into service. When checking for gas leaks, use a soap and water solution; never use an open flame.

with a maximum pressure drop of

19 of 57

Page 28

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Figure 13: Gas Connection

20 of 57

Page 29

SECTION 10: WIRING

DANGER

Electrical Shock Hazard

Disconnect electric before service.

More than one disconnect switch may be required to disconnect electric from heater.

Heater must be properly grounded.

Failure to follow these instructions can result in death or electrical shock.

All heater models require constant 120 V/1Ø/60 Hz power supply. Check heater serial plate for electrical rating for proper circuit sizing. For servicing, a disconnect switch of proper electrical rating should be installed in the vicinity of the heater.

SECTION 10: WIRING

All heaters are equipped with thermostat connections suitable to power a 24 V thermostat.

Heater must be wired and electrically grounded in accordance with local codes. In the absence of local

codes in accordance with: United States: refer to National Electrical Code

NFPA 70 - latest revision Canada: refer to Canadian Electrical Code CSA C22.1 Part I - latest revision.

10.1 Positioning Thermostats

A room thermostat should be mounted on a vibration-free wall or column at a height of approximately 5' (1.5 m) from the floor to measure the ambient temperature. It should be clear of both cold drafts and the direct path of warm air from the heater. Avoid mounting thermostat on outside walls or in areas directly exposed to radiant heat or sunlight. Install wall tag in a visible location near thermostat. See Page 5, Section 2.1 for wall tag details.

10.2 Low Voltage Thermostat with One Heater for Models UHD[T][X][S][R] 150-250

24 Volt Thermostat Heating Only

NOTE: Electrical supply is located below terminal strip.

24 Volt Thermostat with Fan Control

Terminal

Strip

CWGR

Gas Supply

Terminal

Strip

CWGR

Gas Supply

21 of 57

Page 30

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

10.3 Low Voltage Thermostat with One Heater for Models UHD[X][S][R] 300-400

22 of 57

Page 31

10.4 UHD[X][S][R] Series Internal Wiring Diagram for Single Stage Gas Valves

IMPORTANT:

For field wiring into service junction box, or if any of the original wire supplied with the heater must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C (221° F) and 600 V. For supply connections, use No. 14 AWG or larger wires.

SECTION 10: WIRING

23 of 57

Page 32

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

IMPORTANT:

FLAME

SENSOR

PRESSURE SWITCH

THERMOSTAT CONNECTION

120 VAC

TRANSFORMER

FLUE BLOWER

GAS

VALVE

ELECTRODE

IGNITION MODULE

FLAME

SPARK

LIMIT SWITCH

LIMIT SWITCH (UHD 300, 350, 400 ONLY)

MANUAL RESET LIMIT SWITCH (UHD 75 ONLY)

FLUE BLOWER

10.5 UHD[X][S][R] Series Ladder Wiring Diagram for Single Stage Gas Valves

24 of 57

Page 33

10.6 UHD[T][X][S][R] Series Internal Wiring Diagram for Two Stage Gas Valves

HIGH/LOW CONTROL

HIGH

LOW

COMMON

IMPORTANT:

SECTION 10: WIRING

25 of 57

Page 34

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

NOTE:

For field wiring into service junction box, or if any of the original wire supplied with the heater must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C (221° F) and 600 volts. For supply connections use No. 14 AWG or larger wires.

10.7 UHD[T][X][S][R] Series Ladder Wiring Diagram for Two Stage Gas Valves

HIGH

STAGE

26 of 57

Page 35

10.8 Electrical Connection to the Heater

SECTION 10: WIRING

IMPORTANT: Junction box is not provided with heater.

Conduit can also be attached directly to heater with wire junction made within the heater cabinet.

27 of 57

Page 36

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be connected to a properly grounded electrical source.

SECTION 11: OPERATION AND MAINTENANCE

Read this manual carefully before installation, operation, or service of this equipment. All components are accessed via the hinged door. Opening the door exposes live electrical connections and hot components.

Prior to any maintenance or service of the heater, shut off, lockout and tagout the electrical disconnect and gas valve that supplies the unit in accordance with OSHA regulations.

11.1 Pre-Start-Up Checks

All pre-start-up checks must be carried out before lighting the heater.

Ensure that the heater and all controls are suitable for the gas, pressure and electrical supply to which they are to be connected.

11.1.1 Electrical Checks

1. Check that all site wiring is connected in accordance with the appropriate wiring diagram

on Page 23, Section 10.4 or Page 25, Section

10.6.

11.1.2 Gas Supply

All aspects of the gas installation including the gas meter must be inspected, tested for gas tightness 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.

28 of 57

11.1.3 Mechanical Checks

1. Check that the flue (and air intake for separated combustion units) is installed in accordance with the instructions in this manu regulations. See Page 12, Section 7.

11.2 Begin Start-Up

11.2.1 Before Operating the Heater

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 and power supply turned on.

1. Turn off the isolating gas valve.

2. Turn up the thermostat above room temperature. The automatic ignition sequence will now begin as described on Page 29, Figure 14.

There will be no ignition of the burner and lockout will occur, which proves the controls are operating correctly.

11.2.2 Turning Off the Heater

Set the thermostat to the setting and the main burner will stop.

"OFF" position or lowest

al and local

Page 37

Figure 14: Automatic Burner Control Sequence

Burner Sequence for Ignition Control

Flame Signal

Start Gas Valve

Ignition Spark

Thermostat 24 V

SHUT DOWN

RUNSTART

ts = 10 Seconds

Signals Output By Control

Required Incoming Signals

Flue Blower

Pressure

Switch

30 Seconds Purge*

*Purge time begins at pressure switch change over.

30 Seconds Post Purge

If at any stage the flame fails, the control will retry for ignition. The control has four trials for ignition before a one hour lockout.

½PSI IN

OFF

Regulator

Outlet Pressure

Gas Inlet

Inlet Pressure

TOP VIEW

END VIEW

Description Part Number

Gas Valve 150 - 250 NG 90032505 Gas Valve 150 - 250 LP 90032506 Gas Valve 300 - 400 NG 90032520 Gas Valve 300 - 400 LP 90032521

SECTION 11: OPERATION AND MAINTENANCE

Figure 15: Single Stage Gas Valve for Models UHD[X][S][R] 150 – 400

29 of 57

Page 38

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

½PSI IN

OFF

Regulator

Outlet Pressure

Gas Inlet

Inlet Pressure

TOP VIEW

END VIEW

Description Part Number

Gas Valve 150 - 250 NG 90032530 Gas Valve 150 - 250 LP 90032531

Figure 16: Two Stage Gas Valve for Models UHD[T][X][S][R] 150 - 250

30 of 57

Page 39

SECTION 11: OPERATION AND MAINTENANCE

11.2.3 Start-Up the Gas Valve (All Gases)

11.2.3.1 Check Burner Gas Pressure

1. Re m ov e t h e p l ug in the outlet (burner) pressure test point and connect a pressure tap and a manometer.

2. With the burner firing, measure the pressure on the manometer. To adjust the burner pressure, remove the regulator cover from the valve and turn the regulator adjustment screw to set the required burner pressure as stated in the Technical Data Table for the correct gas and model on Page 53, Section 16.3 and Page 55, Section 16.6.

NOTE: For two stage valve (High/Low operation) check burner pressure in both operation modes. To adjust the burner pressure, remove plastic cover from regulators and adjust High and/or Low regulators as needed.

NOTE: If the correct burner pressure cannot be reached, then check the inlet pressure to the valve

with the burner firing. See Technical Data Table on Page 53, Section 16.3 and Page 55, Section 16.6

for inlet pressure req

uirement.

11.4 External Controls

External controls may include time switch, interlock switch, room thermostat and frost thermostat. Operate each control to ensure that they function correctly. Set the switches (if equipped) and thermostat(s) to the users’ requirements.

11.5 Complete Start-Up

Ensure that all covers are fitted correctly and all test points are properly sealed.

11.6 Instruction to the User

Explain the controls of the heater to the user including how to turn it on and off, using the controls equipped on site.

Give this manual to the user. Ensure that the user is shown and understands the

importance of maintaining clearances to combustibles on Page 7, Figure 4, installer responsibility on Page 5, Section 2 and user instructions on Page 32, Section 12 and all warnings defined in this manual.

Do not continue to adjust the regulator if the pressure is not changing.

If the inlet pressure is too low to allow correct burner pressure setting, then the gas inlet pressure must be corrected before completing the start-up.

11.2.3.2 Check Gas Rate

1. Af t e r burner pressure adjustment, allow the heater to operate for at least 15 minutes and then re-check settings. Adjust pressure setting if necessary.

2. Check gas flow rate at gas meter. For two stage valve, (High/Low operation) check gas flow in both operating modes.

3. Turn off heater and electrical supply.

4. Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap.

11.3 Pressure Switch

The pressure switch is factory pre-set for each model and is not adjustable.

31 of 57

Page 40

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be connected to a properly grounded electrical source.

SECTION 12: USER INSTRUCTIONS

The UHD[T][X][S][R] Series heaters are fully automatic and operate from the external controls fitted on site.

12.1 Heater Operation

When the heater has been switched on by the thermostat installed on site, the main burner will automatically turn on.

The burner control module will control the safe ignition of the flame.

For equipment with two stage gas valve, the heater may start in low or high fire.

All heaters require a constant gas and electricity supply which must not be interrupted during the normal operation of this heater.

12.2 Lighting Instructions

12.2.1 To Turn On Heater

1. E n s ure that the electrical and gas supplies to the heater are on. Check that the on site controls are

IMPORTANT: 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 29, Figure 14. The heater

will now operate automatically under the control of the on site controls.

12.2.2 To Turn Heater Off

Set the thermostat to the setting.

The burner will turn off immediately. To re s t a r t , turn the thermostat on or above room

temperature.

12.3 Simple Troubleshooting

Some possible reasons for the heater not operating are:

32 of 57

"ON".

"OFF" position or lowest

1. Ga s s upply not

2. Electricity supply not

3. The time and/or temperature controls are not

"ON".

4. A limit switch may have operated. This may be caused by an interruption of the electrical supply, failure of the distribution fan or vent or heat exchanger blockage.

If a temperature limit switch persistently trips, there is a fault which must be investigated by a contractor qualified in the installation and service of gas-fired heating equipment.

12.3.1 Simple Troubleshooting (Burner Faults)

If the burner fails to ignite for any reason, it will retry for ignition (four trials total). After four unsuccessful ignition trials, the control will put the heater into lockout for one hour.

Lockout should not occur during normal operation of the heater and indicates there is a fault condition which must be corrected. There is an LED light on the ignition control that flashes codes to assist in fault correction. See Page 32, Figure 17 for LED indication codes.

Figure 17: LED Diagnostic Codes

LED INDICATION FAULT MODE

Slow Flash Normal Operation - No call for heat.

Fast Flash Normal Operation - Call for heat.

2 Flashes Ignition Lockout - No flame detected.

3 Flashes Airflow Fault - Pressure switch open or closed.

4 Flashes Temperature Limit Switch Open

5 Flashes Flame Sense Error - Gas valve not energized.

Steady On Internal Control Failure

Page 41

SECTION 13: SERVICING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be connected to a properly grounded electrical source.

SECTION 13: SERVICING

13.1 Servicing Instructions

After start-up, the heater will require maintenance to be carried out, at a minimum, annually. If the heater is used in a dirty or dusty area, more frequent maintenance may be required.

IMPORTANT: Prior to any maintenance or service of the heater, shut off, lockout and tagout the electrical disconnect and gas valve that supplies the unit in accordance with OSHA regulations. After any maintenance or repair work, always test fire the heater in accordance with the start-up instructions

on Page 28, Section 11 through Page 31, Section

11. 6 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 37, Section 14 through Page 41, Section

14.5.

IMPORTANT: Check all gas pipes and pipe joints to ensure there are no cracks or gas leaks. Any cracks in the pipes or pipe joints must be repaired.

IMPORTANT: Inspect all suspended components and hardware. Ensure that they are in good condition, properly tightened, and corrosion free.

13.2 Burner Maintenance

13.2.1 Burner Maintenance for Models 150-250

1. Open the hinged door via tooled access and remove from the hinges. Set door aside. See Page 43, Section 15.2.

2. Remove the filler panel (10 screws) to fully access the burner assembly. See Page 43,

Section 15.2.1.

3. Remove burner assembly from cabinet via screws around the burner assembly (quantity will vary). See Page 43, Section 15.2.1.

Electrode and flame probe should remain attached.

4. Remove manifold from burner assembly via four screws, two on top and two on bottom. See Page 44, Section 15.2.2. Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner.

5. Check condition of ignition electrode and flame probe. Clean off any deposits which may have formed, check condition of ceramic insulators. Replace as required. See Page 46, Section

15.4.

13.2.2 Burner Maintenance for Models 300-400

1. Open the hinged door via tooled access and remove the burner compartment cover. See Page 43, Section 15.2.

2. Remove burner assembly from cabinet via screws around the burner assembly (quantity will vary). See Page 45, Section 15.3.

3. Remove manifold from b four screws, two on top and two on bottom. See Page 45, Section 15.3.1. Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner.

4. Check condition of ignition electrode and flame probe. Clean off any deposits which may have formed, check condition of ceramic insulators. Replace as required. See Page 47, Section

15.5.

13.3 Heat Exchanger Maintenance

The heat exchanger will remain clean unless a problem has developed with combustion. Inspect the heat exchanger. Look for signs of overheating at the

urner assembly via

33 of 57

Page 42

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

front of the tubes which may indicate burner over firing or persistently low air flows.

13.4 Gas Valve Maintenance

No regular maintenance is required on this device. To change gas control valves, See Page 42, Section

15.1.

Do not repair or disassemble gas valve.

Replace faulty gas valves with replacement parts sold and supplied by Roberts-Gordon LLC.

13.5 Flue Blower

The flue blower should not require maintenance. However, if the air pressure switch is causing burner lockout, then remove the flue blower from the vent box by unscrewing the screws at the mounting plate. Screw quantity will vary by model size. Remove the screws attaching the mounting plate to the fan inlet.

See Page 48, Section 15.7 through Page 50, Section 15.9. Ensure that the fan is free to run and

that the fan wheel is clean.

13.6 Venting and Air Intake Pipe

Inspect all venting and air intake pipe. Ensure that all seams are sealed and su

spension points secure.

or combustion air pipe is sagging. Check to make sure any insulation is not missing or in poor condition. Replace as necessary. Check all venting and air intake components to ensure they are in good condition, gas tight and corrosion-free.

13.7 Maintenance Checklist Installation Code and Annual Inspections: All

installation and service of ROBERTS GORDON

equipment must be performed by a contractor qualified in the installation and service equipment sold and supplied by Roberts-Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON

manuals and all applicable governmental authorities pertaining to the installation, service, operation and labeling of the equipment.

To help facilitate optimum performance and safety, Roberts-Gordon LLC recommends that a qualified contractor conduct, at a minimum, annual inspections of your ROBERTS GORDON

equipment and perform service where necessary, using only replacement parts sold and supplied by Roberts-Gordon LLC.

Repair suspension points if any part of the venting

Annual Fall Start Up Follow entire start-up procedure at this time and check control settings and

operation.

The Vicinity of the Heater Do not store or use flammable objects, liquids or vapors near the heater.

Immediately remove these items if they are present.

See Page 6, Section 3.

Vehicles and Other Objects

Maintain the clearances to combustibles.

Do not hang anything from, or place anything on, the heater.

Make sure nothing is lodged in between the heat exchanger tubes.

Immediately remove objects in violation of the clearances to combustibles.

See Page 7, Section 4.

Vent Pipe/Terminals Venting must be intact. Using a flashlight, look for obstructions, cracks on the

pipe, gaps in the sealed areas or corrosion.

The area must be free of dirt and dust.

Remove any carbon deposits or scale using a wire brush.

If the vent terminal has a screen built in, remove any dirt, dust or deposits from the screen.

See Page 12, Section 7 through Page 18, Section 8.

34 of 57

Page 43

SECTION 13: SERVICING

Cabinet Exterior After installation, touch up scratches. Periodic painting should be done there-

after as required. Warning labels and logo labels should be legible and accu- rate. Please contact Roberts-Gordon LLC or ROBERTS GORDON

independent distributor if you need replacement warning labels or logo labels.

See Page 2, Figure 1 through Page 4, Figure 3.

Combustion Air Intake Pipe

Intake pipe and inlet must be intact. Look for obstructions, cracks on the pipe, gaps in the sealed areas or corrosion.

The area must be free of dirt and dust.

Clean and reinstall as required.

See Page 18, Section 8.

Heat Exchanger Make sure there are no cracks.

Make sure there is no sagging, bending or distortion.

Clean or replace as required.

Gas Line and Shut-off Valve s

Burner Observation Window

Flue Blower Scroll, Wheel

Check for gas leaks.

See Page 19, Section 9.

Make sure it is clean and free of cracks or holes.

Clean and replace as required.

Compressed air or a vacuum cleaner may be used to clean dust and dirt.

and Motor Inshot Burners and

Orifices

Clear obstructions (even spider webs will cause problems).

Carefully remove any dust and debris from the burner.

Direct-Spark Igniter Replace if there are cracked ceramics, excessive carbon residue, or erosion

of the electrode.

The electrode gap should be 1/8" (3.2 mm).

Thermostat There should be no exposed wire or damage to the device or wiring.

See Page 21, Section 10

Suspension Points Make sure the heater is hanging securely.

Look for signs of wear on the suspension materials or ceiling.

See Page 11, Figure 6.

Silicone Tubing Ensure tight, secure fit on all pressure fittings at pressure switch and vent box.

Gas Valve Verify that cap covering pressure regulator adjustment screw is secure and

has not been tampered with.

Verify all wiring connections.

Condensate Drain

Flush drain and clear any obstructions.

(when installed)

35 of 57

Page 44

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Ductwork Consult an indoor air quality professional for proper cleaning procedures

Air Circulation Blower For a complete inspection, see the manufacturer’s Installation, Operation and

Service manual.

Wall Tag If wall tag is present, make sure it is legible and accurate. Please contact

Roberts-Gordon LLC or your ROBERTS GORDON

independent distributor if

you need a wall tag. See Page 5, Section 2.1.

36 of 57

Page 45

SECTION 14: TROUBLESHOOTING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, electric shock, injury or property damage.

Burn Hazard

Allow heater to cool before service.

Tubing may still be hot after operation.

Explosion Hazard

Turn off gas supply to heater before service.

DANGER

Electrical Shock Hazard

Disconnect electric before service.

Heater must be connected to a properly grounded electrical source.

SECTION 14: TROUBLESHOOTING

37 of 57

Page 46

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

14.1 General

38 of 57

Page 47

14.2 Troubleshooting For Automatic Ignition Burner Systems

For optimum heater performance, use only replacement parts sold and supplied by Roberts-Gordon LLC.

Conduct start-up procedure as shown on Page 28, Section 11.

SECTION 14: TROUBLESHOOTING

39 of 57

Page 48

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC.

To measure flame current, connect a 0 - 50 μA DC meter in series with the flame probe. If the meter reads negative values, then reverse the test leads.

Repair or replace as

required.

Replace ignition control.

Use General

Trou bleshooting section to

trace the fault.

Heater Operating

TROUBLESHOOT ENDS.

Repair or replace as

required.

Is inlet burner gas pressure

correct? Is live and neutral

polarity correct? Is

flame probe circuit correct?

Is there a current flowing in

the flame probe circuit with

no flame present?

Ye s

Does “lockout” occur when

there is a flame present?

Ye s

Is the connecting lead damaged? Is the flame probe damaged or touching earthed

components?

Is the flame present and

at least 1 μA DC flame

current?

Connect a DC ammeter in

series with the flame probe.

Ye s

START

If problems persist, contact

Roberts-Gordon LLC at

www.robertsgordon.com or

www.rg-inc.com

14.3 Troubleshooting for Flame Supervision System

40 of 57

Page 49

14.4 Troubleshooting for Gas Valves

Valve faulty.

Replace with one of

correct type.

Fault elsewhere.

Correct pressure problem.

Valve Operating

TROUBLESHOOT ENDS.

Ye s

Valve or ignition control

faulty. Replace with one of correct type.

Does gas pressure at

outlet of valve return to zero or

lower when valve turns off?

Ye s

Does gas pressure at outlet

of the valve rise when

valve turns on?

Ye s

Is gas pressure at inlet of the

valve correct for gas type?

Note pressure found.

Ye s

START

If problems persist, contact

Roberts-Gordon LLC at

www.robertsgordon.com or

www.rg-inc.com

For optimum heater performance, use only replacement parts sold and supplied by Roberts-Gordon LLC.

Conduct start-up procedure as shown on Page 28, Section 11.

SECTION 14: TROUBLESHOOTING

14.5 Troubleshooting for Flue Blower

START

Does flue blower run

automatically when there

is a call for heat?

Ye s

Does blower turn on and

off while burner is firing

continuously?

Blower Operating

TROUBLESHOOT ENDS.

Ye s

Correct power

supply problem.

Ye s

Blower motor faulty.

Replace with correct type.

Check blower motor leads

for loose connections.

If problems persist, contact

Roberts-Gordon LLC at

www.robertsgordon.com or

www.rg-inc.com

41 of 57

Page 50

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Carbon Monoxide Hazard

WARNING

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.

Explosion Hazard

DANGER

Electrical Shock Hazard

Fire Hazard

Single Stage

Gas Valve

Two Stage

Gas Valve

½PSI IN

OFF

½PSI IN

OFF

Description Part Number

Single Stage Gas Valve, NG (Models UHD[X][S][R] 150 - 250) 90032505 Single Stage Gas Valve, LP (Models UHD[X][S][R] 150 - 250) 90032506 Single Stage Gas Valve, NG (Models UHD[X][S][R] 300 - 400) 90032520 Single Stage Gas Valve, LP (Models UHD[X][S][R] 300 - 400) 90032521 Two Stage Gas Valve, NG (Models UHD[T][X][S][R] 150-250) 90032530 Two Stage Gas Valve, LP (Models UHD[T][X][S][R] 150-250) 90032531

SECTION 15: REPLACEMENT PARTS

See warnings and important information on Page 33, Section 13 before removing or replacing parts.

Burner Components

All serviceable burner parts are accessed by the hinged door on the side of the heater.

15.1 Gas Valve

Remove the gas supply pipe at the heater inlet.

Follow instructions on Page 43, Section 15.2 through Page 45, Section 15.3.1 to remove gas valve/manifold.

Replace in reverse order. Verify that the gas flow direction of the valve is correct. Use a minimum amount of gas seal on the thread joint. Check that all the joints are leak free. Reset gas valve. See Page 31, Section 11.2.3.

IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS.

42 of 57

Page 51

15.2 Burner Compartment for Models UHA[T][X][S][R] 150-250

Side View of Burner Compartment with Hinged Door Removed

Before burner removal, remove the 10 screws holding the filler panel on and remove the filler panel.

Side View of Burner Compartment with Filler Panel Removed

Burner assembly must be removed to service orifices, manifold or burners.

Following any work, refit components in reverse order.

SECTION 15: REPLACEMENT PARTS

15.2.1 Burner Compartment without Filler Panel for Models UHA[T][X][S][R] 150-250

43 of 57

Page 52

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Remove 4 screws to remove manifold.

Ensure gas tight fitting of injectors. Ensure correct alignment with burners. Ensure all pipe joints are gas tight.

15.2.2 Burner Injectors for Models UHD[T][X][S][R] 150-250

MODEL UHD[T][X][S][R]150 UHD[T][X][S][R]175 UHD[T][X][S][R]200 UHD[T][X][S][R]225 UHD[T][X][S][R]250

Orifice Quantity 7 8 9 10 11

Natural Gas

Orifice Marking 43 43 2.25 mm 2.25 mm 2.25 mm

P/N 91930043 91930043 91930225 91930225 91930225

Propane

Orifice Marking 1.35 mm 1.35 mm 54 54 54

P/N 91930135 91930135 91930054 91930054 91930054

44 of 57

Page 53

15.3 Burner Compartment for Models UHD[X][S][R] 300-400

Remove flexible

air duct from spigot

Remove

access plate

Remove screws and

pull off burner

compartment cover

Viewing port

for flame probe

Viewing port

for ignition electrode

Flame Probe

Burner

Compartment

Cover

Rubber Seal

Ignition Electrode

The burner compartment is a sealed compartment. Following any work, re-seal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight.

NOTE: Flexible duct only applies for

model UHDS.

Screws

Manifold

Inshot

Burners

Orfices

Burner

Screws

Burner venturi

Unscrew

Orfice

Manifold

Marking

Inshot

Burner

Ensure gas tight fitting of injectors. Ensure correct alignment with burners. Ensure all pipe joints are gas tight.

Burner assembly must be removed from unit before the manifold can be removed.

SECTION 15: REPLACEMENT PARTS

15.3.1 Burner Injectors for Models UHD[X][S][R] 300-400

MODEL UHD[X][S][R]300 UHD[X][S][R]350 UHD[X][S][R]400

Orifice Quantity 12 14 14

Natural Gas

Orifice Marking 40 40 40

P/N 91930040 91930040 91930040

Propane

Orifice Marking 1.45 mm 53 53

P/N 91930145 91930053 91930053

45 of 57

Page 54

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Description Part Number Qty.

Spark Electrode 90427411 1 Automatic Ignition Flame Probe 90439300 1 Transformer 90436900K 1 Ignition Module 90434008 1 Inshot Burners UHA[T][X][S] 150 92000001 7 Inshot Burners UHA[T][X][S] 175 92000001 8 Inshot Burners UHA[T][X][S] 200 92000000 9 Inshot Burners UHA[T][X][S] 225 92000000 10 Inshot Burners UHA[T][X][S] 250 92000000 11 Limit Switch (150 - 400) [300 - 400 LOWER] 90412103 1

To replace the ignition electrode or flame probe, remove the electrical lead and screw. Pull out from mounting. Refit in reverse ensuring that the gap to burner is as shown in the front view of the burner compartment.

15.4 Ignition Electrode and Flame Probe for Models UHD[T][X][S][R] 150-250

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Page 55

SECTION 15: REPLACEMENT PARTS

Inshot

Burners

Inshot

Burners

Burner Compartment

Front Views

Flame Probe

Flame

Probe

.120

(3 mm)

spark

gap

Ignition

Electrode

Limit

Thermostat

Remove

Screw

Ignition

Electrode

Remove all

burner compartment

screws to remove

the burner

compartment and

access the

“Front View”

Inshot

Burners

Flame

Probe

Description Part Number Qty.

Spark Electrode 90427411 1 Automatic Ignition Flame Probe 90439300 1 Transformer 90436900K 1 Ignition Module 90434008 1 Inshot Burners UHD[X][S][R] 300 92000000 12 Inshot Burners UHD[X][S][R] 350 92000000 14 Inshot Burners UHD[X][S][R] 400 92000002 14 Limit Switch (150 - 400) [300 – 400 LOWER] 90412103 1 Limit Switch (300 - 400) [UPPER] 90412105 1

To replace the electrode or flame probe, remove the electrical lead and screw. Pull out from mounting. Refit in reverse ensuring that the gap to burner is as shown in the front view of the burner compartment.

15.5 Ignition Electrode and Flame Probe for Models UHD[X][S][R] 300-400

47 of 57

Page 56

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Rear Panel

Gasket

Mounting

Plate

Flue Fan

Vent Box

Rear Panel

Flue Fan

Vent Box

Gasket

Remove screws securing outlet flange to the flue adapter.

Refit in reverse order.

Disconnect electrical connections at plug in tabs.

Remove screws securing flue fan mounting plate to vent box.

Remove screws securing mounting plate to fan. (Not shown)

Refit in reverse.

Use new gaskets.

Ensure sealed joints.

Ensure mounting plate orifice is clear and not obstructed.

15.6 Heat Exchanger

The heat exchanger consists of a four-pass design with 1.75" outer diameter [409 stainless steel] tube. The tube plates are made of [aluminized steel] [409 stainless steel]. The tube supports are made of [aluminized steel] [409 stainless steel].

15.7 Flue Blower for Models UHD[T][X][S][R] 150-175

MODEL

Flue Blower P/N 90710405

IT IS IMPORTANT THAT ONLY THE CORRECT FLUE BLOWER SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS.

Carry out a start-up after working on or changing a flue blower. See Page 28, Section 11.

48 of 57

UHD[T][X][S][R]

150 - 175

Page 57

15.8 Flue Blower for Models UHD[T][X][S][R] 200-250

Outlet Gasket (Inside of Rear Panel)

Mounting Plate

Flue Fan Gaskets

Fan Plate Screws

Remove screws securing outlet flange to the flue adapter.

Refit in reverse order.

Disconnect electrical connections at plug in tabs.

Remove screws securing flue fan mounting plate to vent box.

Remove screws securing mounting plate to fan. (Not shown)

Refit in reverse.

Use new gaskets.

Ensure sealed joints.

Ensure mounting plate orifice is clear and not obstructed.

SECTION 15: REPLACEMENT PARTS

UHD[T][X][S][R]

MODEL

Flue Blower P/N 90710403

200 - 250

IT IS IMPORTANT THAT ONLY THE CORRECT FLUE BLOWER SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS.

Carry out a start-up after working on or changing a flue blower. See Page 28, Section 11.

49 of 57

Page 58

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Vent Box

Outlet Gasket

Flue Blower

Vent Box

screws

Flue

Adapter

Flue Adapter

to Flue Blower

screw

Rear Panel

Hole

Disconnect

electrical connections

at plug in tabs.

Mounting Plate

to Vent Box

screws

Gasket

Mounting Plate

to Flue Blower

screws

Vent Box

Air Plate

Remove screws securing outlet flange to the flue adapter.

Refit in reverse order.

Remove screws securing flue blower mounting plate to vent box.

Remove screws securing mounting plate to blower.

Refit in reverse.

Use new gaskets.

Ensure sealed joints.

Ensure mounting plate orifice is clear and not obstructed.

15.9 Flue Blower for Models UHD[X][S][R] 300-400

MODEL

Flue Blower P/N 90710403 90710402

IT IS IMPORTANT THAT ONLY THE CORRECT FLUE BLOWER SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS.

Carry out a start-up after working on or changing a flue blower. See Page 28, Section 11.

UHD[X][S][R] 300 UHD[X][S][R] 350 - 400

50 of 57

Page 59

15.10 Pressure Switch

SECTION 15: REPLACEMENT PARTS

Pull off 3 way connector. Spring open plastic clips of mounting cradle. Replace with correct type of pressure switch for model. The pressure switches are color coded for each pressure setting. Carry out a start-up after working on or changing a pressure switch. See Page 28, Section 11.

MODEL

Pressure Switch Kit P/N

Color Code yellow orange orange brown orange

Set Point (in wc) 0.32 0.79 0.18 0.68 0.79

Pressure Switch Snap Ring P/N 90439850 90439850 90439850 90439850 90439850

UHD[T][X][S][R]

150 - 175

90439802 90439808 90439812 90439807 90439808

UHD[T][X][S][R]

200 - 225

UHD[T][X][S][R]

250

UHD[T][X][S][R]

300 - 350

UHD[T][X][S][R]

400

15.11 Ignition Control

The control mounts to the electrical plate. Pull out ignition cable and wiring from board, noting their positions. Release the four mounting standoffs. Refit in reverse. Ensure correct location of ignition cable and all other wiring.

15.12 Limit Switches

15.12.1 Removal and Replacement

1. Remove the electrical connections to the switch.

2. Unscrew the two screws securing the switch.

3. Fit a new switch with two screws.

4. Reconnect the electrical connections and test operation.

51 of 57

Page 60

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 16: SPECIFICATIONS

16.1 Dimension Data for Models UHD[T][X][S][R] 150-250

Model UHA[T][X][S]150 UHA[T][X][S]175 UHA[T][X][S]200 UHA[T][X][S]225 UHA[T][X][S]250

A in (cm) 42.4 (107.7) 42.4 (107.7) 42.4 (107.7) 42.4 (107.7) 42.4 (107.7)

B in (cm) 26.7 (67.8) 26.7 (67.8) 35.0 (88.9) 35.0 (88.9) 35.0 (88.9)

C in (cm) 25.5 (64.8) 25.5 (64.8) 25.5 (64.8) 25.5 (64.8) 25.5 (64.8)

D in (cm) 17.6 (44.7) 17.6 (44.7) 17.6 (44.7) 17.6 (44.7) 17.6 (44.7)

E in (cm) 19.4 (49.3) 19.4 (49.3) 19.4 (49.3) 19.4 (49.3) 19.4 (49.3)

G in (cm) 6.0 (15.2) 6.0 (15.2) 6.6 (16.8) 6.6 (16.8) 6.6 (16.8)

H in (cm) 7.86 (20) 7.86 (20) 8.6 (22) 8.6 (22) 8.6 (22)

J in (cm) 11.65 (29.6) 11.65 (29.6) 17.7 (45) 17.7 (45) 17.7 (45)

K in (cm) 3.4 (8.6) 3.4 (8.6) 8.1 (20.6) 8.1 (20.6) 8.1 (20.6)

L in (cm) 5.7 (14.5) 5.7 (14.5) 5.7 (14.5) 5.7 (14.5) 5.7 (14.5)

M in (cm) 9.2 (23.4) 9.2 (23.4) 10.5 (26.7) 10.5 (26.7) 10.5 (26.7)

N in (cm) 6.5 (16.5) 6.5 (16.5) 6.5 (16.5) 6.5 (16.5) 6.5 (16.5)

P in (cm) 2.0 (5.08) 2.0 (5.08) 2.0 (5.08) 2.0 (5.08) 2.0 (5.08)

52 of 57

Page 61

SECTION 16: SPECIFICATIONS

16.2 General Technical Data Table

UHD

Model

Full Load Amps @ 120 V A 2 2 2 2 2

Minimum Air Volume CFM 1360 1400 2050 2100 2350

Te mp e r at ure Rise @ Minimum Air Volume

Heat Exchanger Pressure Drop @ Minimum Air Volume in wc 0.02 0.03 0.025 0.035 0.05

Maximum Air Volume CFM 5800 6850 7750 8300 8850

Te mp e r at ure Rise @ Maximum Air Volume

Heat Exchanger Pressure Drop @ Maximum Air Volume in wc 0.16 0.29 0.163 0.253 0.35

Flue Size*

Air Intake*

Duct Size (Width)

Duct Size (Height)

Weight (Net)

°F

(°C)

°F

(°C)

(cm)

(71)

(61)

(kg)

[T][X][S][R]

150

(46)

(11)

(71)

(61)

191

(86.6)

UHD

[T][X][S][R]

175

(52)

(11)

(71)

32.5 (83)

211

(95.7)

UHD

[T][X][S][R]

200

(40)

(11)

4 - All Models

(10)

4 - All Models

(10)

(71)

32.5 (83)

239

(108.4)

UHD

[T][X][S][R]

225

(44)

(11)

(71)

32.5 (83)

249

(112.9)

UHD

[T][X][S][R]

250

(44)

(12)

(71)

32.5 (83)

254

(115.2)

* Do not exceed the maximum length of flue stated or heater may not operate properly.

16.3 Technical Data Table

Model

Total In p ut(Btu/h) x (1000) 150 175 200 225 250

Total Output(Btu/h) x (1000) 123 143.5 164 184.5 205

Efficiency % 82 - All Models

Natural Gas Data - Inlet Pressure 5.0 in wc Min., 14 in wc Max.

Burner Pressure in wc 2.9 3.0 3.2 3.4 3.45

LPG / Propane Data - Inlet Pressure 12.0 in wc Min., 14 in wc Max.

Burner Pressure in wc 11.0 11.3 9.5 11.1 11.6

UHD

[T][X][S][R]

150

UHD

[T][X][S][R]

175

UHD

[T][X][S][R]

200

UHD

[T][X][S][R]

225

[T][X][S][R]

UHD

250

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Page 62

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

Rear View

Side View

Top Vie w

4 x

” Captive

Nuts Provided

Support Centers

Heater must be supported at these points from above

or below.

Electrical

Supply

Air Intake

(UHD[X]S[R] only)

Flue

Thermostat Connection

Gas

Supply

Duct Flange

16.4 Dimension Data for Models UHD[X][S][R]300-400

Model A B C D E F G H J K L M N

UHD[X][S][R] 300

UHD[X][S][R] 350

UHD[X][S][R] 400

(cm)

52.3

132.8

52.3

132.8

52.3

132.8

43.2

109.7

43.2

109.7

43.2

109.7

25.5

64.8

25.5

64.8

25.5

64.8

24.7

62.7

24.7

62.7

24.7

62.7

19.4

49.3

19.4

49.3

19.4

49.3

1. 2 5

3.2

1. 2 5

3.2

1. 2 5

3.2

7. 0

17.8

7. 0

17.8

7. 0

17.8

11.2

28.4

11.2

28.4

11.2

28.4

13.8

35.1

13.8

35.1

13.8

35.1

6.2

8.7

22.1

8.7

22.1

8.7

22.1

15.7

2.4

6.1

2.4

6.1

2.4

6.1

6.5

16.5

6.5

16.5

6.5

16.5

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Page 63

SECTION 16: SPECIFICATIONS

16.5 General Technical Data Table

Model UHD[X][S][R] 300 UHD[X][S][R] 350 UHD[X][S][R] 400

Full Load Amps @ 120 V A 2 6 6

Minimum Air Volume CFM 2700 3120 3420

Te mp e r at ure Rise @ Minimum Air Volume

Heat Exchanger Pressure Drop @ Minimum Air Volume in wc 0.02 0.03 0.04

Maximum Air Volume CFM 10200 13600 14200

Te mp e r at ure Rise @ Maximum Air Volume

Heat Exchanger Pressure Drop @Maximum Air Volume in wc 0.27 0.48 0.53

Flue Size*

Air Intake*

Duct Size (Width)

Duct Size (Height)

Weight (Net)

°F

(°C)

°F

(°C)

(cm)

(71)

(61)

(kg)

(47)

(13)

(89)

40.5

(103)

325

(147.4)

(47)

(12)

4 - All Models

(10)

(13)

(89)

40.5

(103)

345

(156.5)

(47)

(12)

(13)

(89)

40.5

(103)

345

(156.5)

* Do not exceed the maximum length of flue stated or heater may not operate properly.

16.6 Technical Data Table

Model UHD[X][S][R] 300 UHD[X][S][R]] 350 UHD[X][S][R] 400

Total In p ut(Btu/h) x (1000) 300 350 385

Total Output(Btu/h) x (1000) 246 287 315.7

Efficiency % 82 - All Models

Natural Gas Data - Inlet Pressure 5.0 in wc Min., 14 in wc Max.

Burner Pressure in wc 2.7 2.7 3.3

LPG / Propane Data - Inlet Pressure 12.0 in wc Min., 14 in wc Max.

Burner Pressure in wc9.4 9.3 11.1

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Page 64

UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL

56 of 57

Page 65

SECTION 17: THE ROBERTS GORDON

UHD-SERIES WARRANTY

ROBERTS-GORDON LLC WILL PAY FOR:

Within 24 months from date of purchase by buyer or 27 months from date of shipment by Roberts-Gordon LLC (whichever comes first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect.

Roberts-Gordon LLC will require the part in question to be returned to the factory. Roberts-Gordon LLC will, at its sole discretion, repair or replace after determining the nature of the defect and disposition of part in question.

ROBERTS GORDON

Replacement Parts are warranted for a period of 18 months from date of shipment from Roberts-Gordon LLC or the remaining ROBERTS GORDON

UHD-Series warranty.

ROBERTS-GORDON LLC WILL NOT PAY FOR:

Service trips, service calls and labor charges. Shipment of replacement parts. Claims where the total price of the goods have not

been paid. Damage due to:

• Improper installation, operation or maintenance.

• Misuse, abuse, neglect, or modification of the ROBERTS GORDON

• Use of the ROBERTS GORDON

UHD-Series in any way.

UHD-Series for

other than its intended purpose.

• Incorrect gas or electrical supply, accident, fire, floods, acts of God, war, terrorism, or other casualty.

• Improper service, use of replacement parts or accessories not specified by Roberts-Gordon LLC.

• Failure to install or maintain the ROBERTS GORDON

UHD-Series as directed in the Installation,

Operation and Service manual.

• Relocation of the ROBERTS GORDON

UHD-Series

after initial installation

• The use of the ROBERTS GORDON

UHD-Series in

a corrosive atmosphere containing contaminants.

• The use of the ROBERTS GORDON

UHD-Series in

the vicinity of a combustible or explosive material.

• Any defect in the ROBERTS GORDON

UHD-Series arising from a drawing, design, or specification supplied by or on behalf of the consumer.

• Damage incurred during shipment. Claim must be filed with carrier.

WARRANTY IS VOID IF:

The ROBERTS GORDON® UHD-Series is not installed by an contractor qualified in the installation and service of gas-fired heating equipment.

Yo u cannot prove original purchase date and required annual maintenance history.

The data plate and/or serial number are removed, defaced, modified or altered in any way.

The ownership of the ROBERTS GORDON is moved or transferred. This warranty is nontransferable.

Roberts-Gordon LLC is not permitted to inspect the damaged controller and/or component parts.

UHD-Series

SECTION 17: THE ROBERTS GORDON® UHD-SERIES WARRANTY

READ YOUR INSTALLATION, OPERATION AND SERVICE MANUAL

If you have questions about your controller, contact your installing professional. Should you need Replacement Parts or have additional questions, call or write RobertsGordon LLC:

Roberts-Gordon LLC

1250 William Street P. O . B ox 4 4 Buffalo, New York 14240-0044 Telephone: +1. 716.852.4400 Fax: +1.716.852.0854 Toll Free: 800.828.7450

www.robertsgordon.com www.rg-inc.com

Roberts-Gordon LLC's liability, and your exclusive remedy, under this warranty or any implied warranty (including the implied warranties of merchantability and fitness for a particular purpose) is limited to providing replacement parts during the term of this warranty.

Some jurisdictions do not allow limitations on

how long an implied warranty lasts, so this limitation may not apply to you. There are no rights, warranties or conditions, expressed or implied, statutory or otherwise, other than those contained in this warranty.

Roberts-Gordon LLC shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the ROBERTS GORDON

UHD-Series. Some

jurisdictions do not allow the exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from jurisdiction to jurisdiction.

Roberts-Gordon LLC shall not be responsible for failure to perform under the terms of this warranty if caused by circumstances out of its control, including but not limited to war, fire, flood, strike, government or court orders, acts of God, terrorism, unavailability of supplies, parts or power. No person is authorized to assume for Roberts- Gordon LLC any other warranty, obligation or liability.

LIMITATIONS ON AUTHORITY OF REPRESENTATIVES:

No representative of Roberts-Gordon LLC, other than an Executive Officer, has authority to change or extend these provisions. Changes or extensions shall be binding only if confirmed in writing by Roberts-Gordon LLC's duly authorized Executive Officer.

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