Roberts Gorden HF 40 v1, HF 40 v2, HF 30 v5, HF 30 v6, HF 40 v3 Installation, Commissioning, Service & User Instructions

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. DO NOT try to light any appliance.

3. DO NOT use electrical switches.

4. DO NOT use any telephone in
your building.

5. Leave the building.

6. Immediately call your local gas
supplier after leaving the building.
Follow the gas suppliers
instructions.

Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appli­ance.

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

WARNING

Improper installation, adjustment, alteration,
service or maintenance can result in death, injury
or property damage. Read the Installation,
operation and service manuals thoroughly before
installing or servicing this equipment

Installation must be done by a contractor qualified
in the installation and service of gas/oil fired
heating equipment (whichever is applicable).

Installer

Please take time to read and understand these

instructions prior to any installation. Installer must

give a copyof this manual to the user/owner.

Owner/User

Keep this manual in a safe place close to the heater

to provide your serviceman with information should it

become necessary.

Roberts-Gordon Europe Ltd.

Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: [phone]
Fax: [phone]
email: [e-mail]

www.combat.co.uk
www.rg-inc.com

Combat

®

Warm Air Cabinet

& High-Flow Heaters

OIL FIRED: POP, POPH and

POP /H versions

Models 015 to 0100

GAS FIRED: PGP, PGPH and

PGP /H/M versions

Models 015 to PGP 0100

Installation, Commissioning,

Service & User Instructions

WARNING

Fire Hazard

X523F 02/03

© Copyright 2002 Roberts-Gordon

Page 1

CABINET HEATER

T

he gas fired versions of these appliances have been tested and certified

as complying with the essential requirements of the Gas Appliance Directive, the
Electromagnetic Compatibility Directive, The Low Voltage directive and the Machinery Directive
for use on natural gas and L.P.G. Propane when installed, commissioned and maintained in
accordance with these instructions

The gas fired heaters are category II

2H 3P

for natural gas or propane gas and are type B23 for

a natural draught flue.

These instructions refer to gas appliances designed to operate in the following countries:
United kingdom (GB), Ireland (IE), Italy (IT) and Spain (ES)

The oil fired versions may also operate in these countries in accordance with local rules and
laws.

The oil fired versions are constructed to the same Basic design criteria to burn fuel oil as
specified below but there is no similar testing available for these products at the time of
writing these instructions.

However the safe operation of the heaters depends on the proper installation, commissioning
and maintenance of the appliances in accordance with these instructions .

The fuel specified for oil fired burners is:

Class D fuel oil to BS 2869
Which is similar to Gas oil with a maximum viscosity at 20° C of 1.5° E

These appliances must be installed in accordance with the rules in force, and used only in a
sufficiently ventilated space, as specified in these instructions and local regulations.

Before installation, check that the local distribution conditions of the fuel, the quality of the
fuel and the appliance adjustment are compatible.

These instructions cover the installation setting and operation of all variations of the COMBAT®
range of cabinet heaters. The burner manufacturers instructions are also provided to give
detailed instructions on the operation of the burner. The settings for use of the burner with
the air heater are shown in these instructions or the relevant supplement which is issued with
the appliance to cover specific features available for various options.

It is important that all of the relevant information is used when installing, setting or operating
this equipment

© 2003

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 written permission of Roberts-Gordon.

Page 2

CABINET HEATER

Contents

The parts of this manual are numbered by section, clause and sub clause. Hence: 1.2.3 refers to Section 1, clause 2,
sub clause 3. Figure numbers also follow this notation hence: Fig 2.3 is Section 2, fig.3.

SECTION PAGE

1. General Specification 3

2. Technical Data 7

3. Installation Requirements 29

4. Installation of the Air Heater 33

5. Commissioning of the Air Heater 39

6. Wiring Diagrams 46

7. Servicing Instructions 56

8. Removal and Replacement of Parts 58

9. Fault Finding Charts 60

10. User Instructions 67

11. Conversion information 72

12. Parts List 73

13. Commissioning Data Sheet 74

THIS MANUAL RELATES TO THE AIR HEATERS WHICH ARE MANUFACTURED FOR USE WITH:-

OIL FIRED HEATERS: GAS FIRED HEATERS

Class D fuel oil to BS 2869 Natural gas G20
Which is similar to L.P.G Propane (G31)
Gas oil with a maximum viscosity at 20° C of 1.5° E

THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR NEAR THE HEATER

Note: Every effort is made to ensure that the information within this manual is accurate.

However, Robert-Gordon reserves the right to alter specifications without prior notice.

Roberts-Gordon shall not be liable to rectify any defects or damage caused by any modifications made or attempted to
be made to the heating units by the customer, his servants, agents or employees.

Page 3

CABINET HEATER

Section 1. General Specification

1.1 General Information - Standard Models

COMBAT® cabinet warm air heaters are self contained units fitted with a packaged burner and are supplied ready for
installation on site to be used with external controls.
The burner controls which form part of the packaged burner are designed for safe operation between

-20°C to 60°C. However the heater should not be operated in ambient temperatures above 32°C .At Ambient temperatures
above 29°C some models may require the maximum heat input to be reduced, seek advice from Roberts-Gordon UK
Ltd. under these circumstances

The standard PGP or POP heater is the free standing model.

Models are available with various options are:

PGPH & POPH models for use in the horizontal (suspended) mode
PGPE & POPE weatherproof models for external siting
HF range of 'High Flow' gas fired and oil fired heaters with higher air flows
PGP/H and HF/H gas fired ranges for Ecoflam high /low burners
PGP/M and HF/M gas fired ranges for Ecoflam fully modulating burners
POP/H and HF/H oil fired ranges are also available with Ecoflam High /Low burners

COMBAT® cabinet heaters are available with heat outputs ranging from 47.3kW to 290kW.

All heaters are fitted with fully automatic 'packaged' forced draught oil fired or gas fired burners manufactured for
Roberts-Gordon UK Ltd.

The heater cabinets are manufactured in Zintec coated mild steel which is finished with a stove cured powder coat
paint.

The combustion chambers are of high grade stainless steel construction. The heat exchangers are mild steel tubular
all welded construction.

Centrifugal fan(s) located in the base of the heater cabinet provide heated recirculation air, which is distributed from the
top of the heater through the fully adjustable louvred outlet heads.

The fan(s) are either direct drive or belt driven dependent upon model:

Models 015 - 050 inclusive - Direct Drive (except High Flow)
Models 060 - 0100 inclusive - Belt Drive

The required electrical supply is: 230 volt 50Hz single phase on models 015 to 030 and 400 volt 50Hz three phase
and neutral on models 040 to 0100 (Models PGP and POP 040 and 050 are also available as single phase belt drive
to special order). All High Flow models require a 400V, 50Hz, three phase and Neutral electrical supply.

ON/OFF control, temperature control, time control, and frost protection are available as a remote control which needs
to be site wired to afford proper operation of the heater. Alternatively, any remote energy controls may be used which
must be installed in accordance with Section 4.3.

Each heater must be fitted with its own natural draught flue in accordance with local regulations and the instructions in
this booklet. Fig. 1.1 shows the basic parts of the heater.

Page 4

CABINET HEATER

Fig 1.1 Standard PGP/POP Cabinet Heater - General Arrangement

Air Diffuser Heads

Fan/Limit Thermostat

Flue

Flue Spigot (female)

Heat Exchanger

Rear Pressure Relief

Stainless Steel
Combustion Chamber

Double Skin Panels

Burner Tube (for
mounting the 'packaged'
burner)

Electrical Connections

Lower Front Panel

Main Fan Assembly
(Direct Drive on
Models 15 - 50,
Belt Dive on
Models 60 -100)

Page 5

CABINET HEATER

1.2 Basic Information - High Flow (HF) Models

1.2.1 Introduction

The COMBAT® HF range of cabinet heaters are designed specifically to meet the needs of designers who require a
high fan performance with the heat input that would be expected for the standard COMBAT® cabinet range of heaters.
The result of this is to produce a lower average temperature rise over the heat exchanger dependant upon the final air
flow of the installation.

High Flow Heaters are fitted with burners to the same specification as the PGP or POP 30 to 50 models for either gas
or oil firing.

COMBAT® High Flow cabinet heaters are available in 10 sizes dependent upon air flow required, with a choice of 3
heat outputs; 81kW, 115kW and 145kW.

1.2.2 Electrical Supply

The HF range of heaters all require a 400v three phase and neutral 50Hz supply to the main terminals within the heater.

1.2.3 Controls

The HF range of heaters are designed to be operated with external controls and are provided with electrical terminals
to accommodate these.

They may be controlled in the same manner as the PGP or POP models using Roberts-Gordon controls or other
suitable controls.

1.2.4 Fan Operation

All of the HF range of heaters are provided with a fan operation relay as well as the combination fan thermostat to
ensure that the fan will run correctly even though the temperature rise may be low.

The HF 40v3 and HF 50v2 to 50 v4 models are fitted with 5.5kW or 7.5kW motors that are controlled via an automatic

star/delta starter built into the heater to replace the direct on line starter used for the remainder of the range.

Page 6

CABINET HEATER

1.3 Heater Operation (On/Off)

Once the heater has initially been switched on using the remote controls, the operation of the heater becomes automatic
under the control of the remote time/temperature controls (as fitted on site) and the safety devices.

When the external controls call for heat, the control box of the fully automatic burner checks that all systems are in a
safe and ready position, and then initiates a start sequence. It then constantly monitors safe operation of the burner
(see Section 2.2 & 2.3 for details).

When the heat exchanger has been sufficiently heated, the built in fan thermostat turns on the main fan(s) and warm
air is distributed from the top of the heater.

Note: On horizontally mounted heaters, High Flow heaters, heaters fitted with high/low or modulating burners and
some fully ducted heaters, the fan will come on during the burner firing cycle and not wait for the temperature rise. This
is to ensure that there is always a proper operation of the heater under all possible conditions.

At the close down of the external controls, the burner shuts off and the main fan(s) continue to run until the fan
thermostat detects a drop in leaving air temperature, sufficient to turn it off. The heater is then at rest until the beginning
of the next cycle.

If for any reason the main fan should fail or the air flow through the heater is reduced, then the built in limit thermostat
will cause the burner to go to safety shut down lockout. This condition will remain until the fault is corrected and the
manual red reset button is operated at the limit thermostat.

1.2.1 Heater Operation (High/Low)

For burners which are capable of High/Low operation, a two stage thermostat will be required to be installed on site to
alow the burner to operate On/Off and High/Low dependant upon conditions (see 4.3.1.1 for details)

1.2.2 Heater Operation (Fully Modulating)

For gas burners only which are capable of Fully Modulating operation the burner comes complete with a temperature
control system. The sensor of this system needs to be installed on site (see 4.3.1.2) to allow the burner to vary the heat
input to maintain a constant control temperature.

WARNING

The main electrical isolator should only be used in an emergency and for servicing.

It should never be used for closing down the burner, as this switches off the main fan prematurely

and may damage the heat exchanger, invalidating the warranty and causing a potential fire hazard.

Page 7

CABINET HEATER

Section 2. Technical Data

Table 2.1 General Data All Standard Models PGP and POP and All

Versions for High/Low or Modulating Burners

Dimensions for Horizontal heaters are as above, with heaters lain on their left hand side as standard.

* For vertical models add 54mm (2 ins) to the right hand side of the heater cabinet for the fan/limit thermostat.

* For horizontal models add 54mm (2 ins) to the top of the heater cabinet for the fan/limit thermostat.

Note: A permanent uninterrupted electrical supply is required for all models

A Width

B Depth - Cab.Only

C Height - Cab.Only

D Depth Overall Oil

D Depth Overall Gas

E Height Incl. Heads

F L/R Hand Air

Inlet Spigot Depth

G L/R Hand Air

Inlet Spigot Height

H Rear Air

Inlet Spigot Depth

J Rear Air

Inlet Spigot Height

Weight

Number and size

of air discharge heads

Flue Diameter

MAIN FAN

Motor Type

Motor Size

Motor Pulley

Fan Pulley

Main Fan Start

Current

Main Fan Run Current

Total Elec. Load

Airflow (Free Blowing)

AC Electrical Supply

Model

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

mm (ins)

kgs (lbs)

mm

mm (ins)

kW (hp)

PCD

PCD

amps

amps

kW

M³/hr

ft/hr

Volts

Hertz

Phase

020

724 (28½)

857 (33¾)

1740 (68½)

1220 (48)

1306 (51½)

1988 (78¼)

781 (30¾)

457 (18)

648 (25½)

361 (14)

200 (441)

2 x 229

178 (7)

Dir. Drive

0.75 (1)

n/a

n/a245.3

2.1
3398

(2000)

230

50

1

030

724 (28½)

857 (33¾)

1740 (68½)

1220 (48)

1306 (51½)

2058 (81)

781 (30¾)

457 (18)

648 (25½)

361 (14)

200 (441)

2 x 356

178 (7)

Dir. Drive

0.75 (1)

n/a

n/a286.3

2.1
5097

(3000)

230

50

1

040

857 (33¾)

857 (33¾)

1930 (76)

1254 (49½)

1348 (53)

2235 (88)

781 (30¾)

559 (22)

781 (30¾)

446 (17¾)

245 (540)

2 x 356

178 (7)

Dir. Drive

2.2 (3)

n/a

n/a216.2

5.4
6796

(4000)

400

50

3N

050

857 (33¾)

1016 (40)

1930 (76)

1413 (55¾)

1507 (59½)

2235 (88)

940 (37)

559 (22)

781 (30¾)

446 (17¾)

270 (595)

2 x 356

178 (7)

Dir. Drive

2.2 (3)

n/a

n/a216.2

5.4
8495

(5000)

400

50

3N

060

1016 (40)

1676 (66)

1930 (76)

2251 (88¾)

2388 (94)

2235 (88)

1600 (63)

559 (22)

N/A

N/A

440 (970)

6 x 356

229 (9)

Belt Drive

1.5 (2)
2A x 80mm

2Ax180mm

10.2

3.5

4.4
11044

(6500)

400

50

3N

070

1016 (40)

1676 (66)

1930 (76)

2251 (88¾)

2388 (94)

2235 (88)

1600 (63)

559 (22)

N/A

N/A

440 (970)

6 x 356

229 (9)

Belt Drive

2.2 (3)
2A x 95mm

2Ax180mm

30

5.1

5.5
12443

(7500)

400

50

3N

080

1016 (40)

1676 (66)

1930 (76)

2251 (88¾)

2388 (94)

2235 (88)

1600 (63)

559 (22)

N/A

N/A

440 (970)

6 x 356

229 (9)

Belt Drive

2.2 (3)
2A x 95mm

2Ax180mm

30

5.1

5.5
12443

(7500)

400

50

3N

0100

1016 (40)

1994 (78½)

1930 (76)

2569 (101¼)

2706 (106½)

2235 (88)

1918 (75½)

559 (22)

N/A

N/A

530 (1168)

6 x 356

229 (9)

Belt Drive

4 (5.4)

2A x106mm

2A x 180mm

35

9.6

6.6
17330

(10200)

400

50

3N

015

724 (28½)

857 (33¾)

1740 (68½)

1220 (48)

1306 (51½)

1988 (78¼)

781 (30¾)

457 (18)

648 (25½)

361 (14)

200 (441)

2 x 229

178 (7)

Dir. Drive

0.75 (1)

n/a

n/a245.3

2.1
3398

(2000)

230

50

1

Page 8

CABINET HEATER

Dimensions of outlet spigots - Standard Cabinet Heaters

Dimensions - All Models PGP and POP

Cabinet Sizes 015 - 050 Cabinet Sizes 060 - 0100

Note: Horizontal heater dimensions are as vertical units, but with heaters lain on their left hand side as standard.

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

MODEL

K Spigot Width

L Spigot Depth

mm

(ins)

mm

(ins)

015

648

(25½)

476

(18½)

020

648

(25½)

476

(18½)

030

648

(25½)

476

(18½)

040

781

(30¾)

476

(18½)

050

781

(30¾)

610
(24)

060/070/080

940
(37)

1238

(48¾)

0100

940
(37)

1524

(60)

Air Outlet Spigot Dimensions - Standard Cabinet Heaters

Page 9

CABINET HEATER

Table 2.2 General Data - High Flow Cabinet Heaters

For High Flow PGP and POP range heaters * Start current shown for direct on line starting.

Mod el Numb er HF 30 v4 HF 30 v5 HF 30 v6 HF 40 v1 HF 40 v2 HF 40 v3 HF 50 v1 HF 50 v2 HF 50 v3 HF 50 v4

Product Code HE (O) (G)34 HE(O) (G)35 HE(O) (G) 36 HE(O) (G) 41 HE(O) (G) 42 HE(O) (G) 43 HE (O) (G) 51 HE (O) (G) 52 HE (O) (G) 53 HE (O) (G) 54

Air Volume m³ /sec
Static Pressure Pa See Graph HF 11 See Graph HF 12 See Graph HF 13 See Graph HF 4 See Graph HF5 See Graph HF 6 See Graph HF 7 See Graph HF 8 See Graph HF 9 See Graph HF 10
Motor Running Current
Max Motor start current Amps 27 40 40 20.0 32.0 35.0 D.O.L. * 20.0 35.0 D.O.L. * 37.5 37.5
Max Moto r runnin

g

current Amps (FLC)5 8.4 8.4 5.4 9.4 11.5 8.7 11.5 16.5 18
Max Electrical load (on FLC) kW 4 6.6 6.6 4 6.6 8.3 6.6 8.3 11.9 11.9
Motor Size kW 2.2 4.0 4.0 2.2 4.0 5.5 4.0 5.5 7.5 7.5
Part Number A 064 A 072 A 072 A 064 A 072 A 063 A 072 A 063 A 062 A 062
Motor Pull ey 85 x 28 x 2A 106 x 28 x 2A 112 x 28 x 2A 95 x 28 x 2A 118 x 28 x 2A 140 x 38 x 2B 95 x 28 x 2A 112 x 38 x 2B 132 x 38 x 2B 140 x 38 x 2B
Part Number A 132 A 108 A 411?? A 121 A 418 A 415 A 121 A 403 A 420 A 415
Fan Pul l ey 180 x 25 x 2A 180 x 25 x 2A 180 x 25 x 2A 180 x 25 x 2A 180 x 25 x 2A 200 x 25 x 2B 180 x 25 x 2A 180 x 25 x 2B 200 x 25 x 2B 200 x 25 x 2B
Part Number A 168 A 120 A 120 A 120 A 120 A 413 A 120 A 405 A 413 A 413
Overload size Set at 6.4 Set at 6.4 set at 8.7 set at 8.7

4.0 - 7.5 Amp 6.0 - 10 Am p 6.0 - 10 Amp 4.0 - 7.5 Amp 6.0 - 10 Amp Star.Delta 7.5 A. FLC 6.0 - 10 Amp Star.De lta 7.5 A. FLC Star.Delta 10 A. FLC Star.Delta 10 A. FLC
Part Number D 020 D 024 D 024 D 020 D 024 D 020 A D 024 D 020 A D 024 D 024
Vee Belt Size A49 A49 A49 A49 A49 B54 A49 B50 B52 B52
Part No A 136 A 136 A 136 A 136 A 136 A 408 A 136 A 409 A 410 A 410
Wiring Diagram RDW 1556/D RDW 1556/D RDW 1556/D RDW 1556/D RDW 1556/B RDW 1582/B RDW 1556/B RDW 1582/B RDW 1582/B RDW 1582/B
Cabinet type 50 50 50 60 60 60 100 100 100 100

DIM ENSI ONS

'A' Width mm 857 857 857 1016 1016 1016 1016 1016 1016 1016
'B' Depth Cabinet Only mm 1016 1016 1016 1676 1676 1676 1994 1994 1994 1994
'C' Height Cabinet Only mm 1930 1930 1930 1930 1930 1930 1930 1930 1930 1930
'D' Depth overall (Oil Fired) mm 1326 1326 1326 1996 1966 1966 2314 2314 2314 2314
'D' Depth overall (Gas f ired) mm 1416 1416 1416 2066 2066 2066 2384 2384 2384 2384
'W' Outlet duct dimension Width mm 781 781 781 940 940 940 940 940 940 940
'L' Outlet duct dimension Depth mm 610 610 610 1030 1030 1030 1350 1350 1350 1350
'F' inlet duct dimension Depth mm 940 940 940 1600 1600 1600 1918 1918 1918 1918
'G' Inlet duct dimension Height mm 559 559 559 559 559 559 559 559 559 559

for High Flow PGP and POP range heaters * Start current show n for direct on line starting.

The burne r settings are as shown in the r elevant data table in the m ain instructions book . these models are fitted with star delta starters as standard

Heat inputs shown are m aximum for each version at minimum air flow on graph. Revision correct m otor shaft size for 50 v2 October 10 96

Dimensions - High Flow Cabinet Heaters - All Models

A

B

C

D

W

L

F

G

178

229 (HF30)

435 (HF40)

412 (HF50)

Page 10

CABINET HEATER

Table 2.3 Oil Fired Burner Data (Ecoflam Burner)

Burner Reference "G"

DATA TABLES - IMPORTANT NOTE

When reading the Data Tables 2.3 to 2.9 on the following pages,

ensure that the correct table for the burner and gas valve installed is being used.

The Data Tables are listed under a burner reference letter which can be found

on the heater data plate.

Refer also to the Burner Manufacturer's Instructions

and the specific instructions supplement where applicable.

The burner settings shown in the instructions should be used for burner settings.

Note: High Flow Heaters are fitted with burners to the same specification as the POP 30, 40 and 50 models for oil firing.

Mode l POP 015 POP 020 POP 030 POP 040 POP 050 POP 060 POP 070 POP 080 POP 0100

Heat Input (gross)

Kw 51 73.6 109.7 146.2 183.2 221.2 256.2 300.6 355.8

Btu/hr 174012 251073 374277 498786 625000 754870 874060 1025647 1213874

Nominal He at output

Kw 44 58.6 87.9 117.2 146.5 175.8 205.2 234.5 293.1

Btu/hr 150000 200000 300000 400000 500000 600000 700000 800000 1000000

Ecoflam Burner type

Minor 8 Minor 8 Minor 12 Minor 20 Minor 20 Minor 30 Minor 30 Minor 30 Major 30

Nozzle Size

Us gall/hr 1.00 1.50 2.25 3.00 3.00 4.00 5.00 5.50 7.00

Angle & Type

60S 60S 60S 60S 60S 60A 60A 60A 60A

Make

Danfoss Danfoss Danfoss Danfoss Danfoss Delevan Delevan Delevan Delevan

Head setting

mm 8 0 14

8

(Fully back)8(Fully back)8(Fully back)

8

(Fully back)

8

(Fully bac k )

(Fully

Forward)

Air setting

Number 4.2 8.5 5.5 2.5 4 3.7 4.5 6.2 1.8

Burner fuel

Bar 12 10.3 10.3 10 13.8 12.4 10.7 10 11

pressure

PSI 175 150 150 145 200 180 155 145 160

Fuel

L/hr 4.82 6.96 10.37 13.83 17.32 20.92 24.23 28.43 33.65

consumption

imp gall.hr 1.06 1.53 2.28 3 3.81 4.6 5.33 6.25 7.4

Max. oil pressure

Bar 0.21 0.21 0.21 0.21 0.21 0.21 0 .2 1 0.21 0.21

to pum p inle t

PSI3333333 33

Page 11

CABINET HEATER

Table 2.4 Ecoflam ON/OFF Natural Gas (G20) Dungs Valve, Burner

Reference C

Data for all versions "H" horizontal, "HF" high flow
Gas rates corrected to standard conditions 1013.25 mbar 15°C

HEAD SETTING - See Adjustment Of The Firing Head in Ecoflam Instructions

INLET PRESSURE 20 mbar (Minimum 17 mbar, M ax imum 25 mbar)

MODEL PGP 015 PGP 020 PGP 030 PGP 040 PGP 050 PGP 060 PGP 070 PGP 080 PGP 0100

Gross heat input (kW)

56.1 73. 7 103 144.7 182.1 220 253.6 297 363

Net heat Input (kW)

51 67 93.6 131.5 165. 5 200 230.5 270 330

Ap pr o x heat output (kW)

46.9 60. 3 81.9 114.7 144.8 176 202.8 237.6 290.1

Start Gas Orifice (mm dia.) 5.0 6.0 7.0 7.0 7.0 7.0
Max Gas Rate (Sm

3

/hr)

5.4 7. 1 9.9 13. 9 17.5 21. 2 24.4 28. 6 34.9

Main Burner Gas Pressure (mbar)

4.7 2. 5 4.9 5.2 8.5 5. 6 7.5 9.5 11

Start Gas Pressure (mbar)

N/A N/ A N/A 1.8 2. 8 0.9 1.1 1.7 3.4

BURNER TYPE

A ZUR BLU BLU BLU BLU BLU BLU BLU BLU

60 12 0 120 170 250R 250 250 250S 350
Burner Head sssssssss
Burner Injector
Head Setting (mm)

0 1011151424242421

1st Flame Air Setting

3.5 3.9 8 2.8 5.1 3.3 5.3 2 2

2nd Flame Air Setting
Ga s Valve S etting
Valve Type MBDLE MBDL E MBDLE MBDLE MBDLE MBDL E MBDLE MBDLE MBDLE
Main Gas 405 405 405 407 410 410 4 10 410 412

Valve Type SSSSSS
Start Gas 0 832 051 0 832 051 0 832 051 0 83 2 05 1 0 832 051 0 832 051
AIR PRES SURE SWITCH
SETTING (mbar) 3.8 4.5 5.9 2.9 5.5 3.6 4.5 6.8 5.1
Max flue static pressure
norm. flue static pressure ( mbar) -0.05 -0 .05 -0.09 - 0 .30 -0.05 - 0.25 -0.17 0.10 0.45
Gas Connection 3/4" 3/4" 3/4" 3/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4"
S.= S.I T
H.= HONEYWELL

Page 12

CABINET HEATER

Table 2.5 Ecoflam ON/OFF LPG (G31) with Dungs Valve, Burner Reference C

Data for all versions "H" horizontal, "HF" high flow
Gas rates corrected to standard conditions 1013.25 mbar 15°C

HEAD SETTING - See Adjustment Of The Firing Head in Ecoflam Instructions

INLET PRESSURE 37 mbar (MINIMUM 25 mbar , MAXIMUM 45 mbar)

MODEL PGP 015 PGP 020 PGP 030 PGP 040 PGP 050 PGP 060 PGP 070 PGP 080 PGP 0100

Gross heat Input (kW)

56.1 73.7 103 144.7 182.1 220 253.6 297 363

Net heat Input (kW)

51 67 93.6 131.5 165.5 200 230.5 270 330

Approx heat output (kW) 46.9 60.3 81.9 114.7 144.8 176.0 202.8 237.6 290.1
Main Gas Orifice (mm dia.) 8.5 10.0 10.0 14.5 14.5 14.5 14.5 14.5
Start Gas Orifice (mm dia.) 5.0 6.0 7 .0 7.0 7.0 7.0
Max Gas Rate (m

3

/hr) 2.10 2.70 3.80 5.40 6.80 8.20 9.40 11.00 13.50
(kg/hr) 3.9 5.1 7.1 10.1 12.7 15.4 17.6 20.6 25.3
Lt/hr 7.7 10.0 13.9 19.8 25.0 30.3 34.6 40.5 49.7

M ain Burner Gas P ressure (mbar) 3.9 3.1 5.6 4.6 7.0 5.2 6.8 9.5 7.6
Start Gas Pressure (mbar) 1.6 2.5 0.8 1.0 1. 5 3.1

BURNER TYPE

AZUR BLU BLU BLU BLU BLU BLU BLU BLU

60 AH 120 AH 120 AH 170 AH 250R AH 250 AH 250 AH 250S AH 350 AH
Burner Head s s s s s s s s s
Burner Injector LPG
Head Setting (mm) 10.0 13.0 15.0 14 24.0 24.0 24.0 20.0
1st Flame Air Setting number 3.8 3.5 6.0 3.5 4.5 3.5 4.7 1.7 3.0
2nd Fl ame Ai r Setting
Gas Valve Setting
Valve Type MBDLE MBDLE MBDLE MB DLE MBDLE MBDLE MBDLE MBDLE MBDLE
Main Gas 405 405 405 407 410 410 410 410 412

Valve Type S S S S S S
Start Gas 0 832 051 0 832 051 0 832 051 0 832 051 0 832 051 0 832 051
AIR PRESSURE SWITCH
SETTING (mbar) 3.8 4.5 5.9 2.9 5.5 3.6 4.5 6.8 5.1
Max flue static pressure
norm. flue static pressure (mbar) -0.05 -0.05 -0.09 -0.30 -0.05 -0.25 -0.17 0.10 0.45
Gas Connection 3/4" 3/4" 3/4" 3/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4"
S.= S I T
H.= HONEYWELL

Page 13

CABINET HEATER

Table 2.6 Ecoflam HIGH/LOW or MODULATING Burner with Dungs

Valve, Burner Reference "H" Natural Gas G20

Data for all versions "H" horizontal, "HF" high flow
Gas rates corrected to standard conditions 1013.25 mbar 15°C

When setting the minimum firing rate a check must be made following the setting of the burner combustion .
The check is made by running the heater on low fire for a minimum of 15 minutes at the full transport air rate and at
typical ambient conditions. During the test check that the flue gas temperature does not fall below 150°C .Should the
flue gas temperature fall below 150°C then the low fire gas setting must be increased to a value that will achieve 150°C
flue gas temperature, otherwise condensation may form in the heat exchanger and flue causing rapid corrosion and
short operational life.

ECOFLAM HIGH/LOW GAS BURNER WITH DUNGS GAS VALVES FOR NATURAL GAS G20

INLET PRESSURE 20 mbar (minimum 17mbar maximum 25mbar)

MODEL PGP 015 PGP 020 PGP 030 PGP 040 PGP 050 PGP 060 PGP 070 PGP 080 PGP 0100

Maximum Gross heat Input (kW) 55.0 74.0 104.0 145.9 183.0 221.0 256.0 300.0 367.0
Maximum Net heat Input (kW) 49.6 66.7 93.7 131.5 164.9 199.1 230.7 270.3 330.7
Minimum Gross heat Input (kW) 33.85 44.40 63.82 87.13 109.88 133.19 153.16 179.80 219.76
Minimum net heat Input (kW) 30.50 40.00 57.50 78.50 99.00 120.00 138.00 162.00 198.00
Approx heat output (N et) (kW) 43.5 58.5 82.2 115.3 144.6 174.6 202.0 237.0 289.9
Start Gas Orifice (mm dia.) 7.0 7.0 7.0 7.0 7.0 7.0
Max Gas Rate

(Sm

3

/hr )

5.2 7.1 9.9 13.9 17.4 21.1 24.4 28.6 35.0

Min Gas Rate

(Sm

3

/hr )

3.1 4.2 6.0 8.5 10.6 13.0 15.0 17.5 21.6
Main Burner Gas Pressure (mbar) 4.7 2.5 4.1 5.2 8.5 5.9 7.5 9.5 9.6
Min . B urner G a s P r e s sure (mba r) 2 .1 2.0 2.2 2.1 3.4 2.1 2.8 3.8 4.5
Start Gas Pressure (mbar) 1.1 1.8 0.6 0.7 0.9 1.0
BURNER TYPE AZUR BLU BLU BLU BLU BLU BLU BLU BLU

60 120 120 170 250R 250 250 250 350
Burner Head sssssssss
Burner Injector
Head Setting (mm) 0.0 8.0 10 .0 15.0 14 T.O . T.O. T.O. T.O.
Low Flame Air Orange C a m ** 20° 13° 22° 18° 18° 18° 22° 25° 25°

High Flame Air Red Cam ** 33° 40° 80° 30° 32° 30° 35° 55° 60°
Ga s Valve Setting 0-1,5 0-1 0-1 ,4 0-1,4 0-1 ,4 0-1 ,4 0-1 ,4 0-1,4 0-1 ,4
Valve Type M BVEF MBVEF MBVEF M BVEF MBVEF MBVEF M BVEF MBVEF MBVEF
Main Gas 407 407 407 407 412 412 412 412 412

Valv e Type S.I.T. S.I.T. S.I.T. S.I.T. S.I.T. S.I.T.
Start Gas 832051 832051 832051 832051 832051 832051
AIR PRESSURE SWITCH
SETTING (mbar) 1.5 1.5 1.5 1.0 1.5 1.5 1.5 2.0 2.5
Max flue static pressure
norm. flue static pressure (mbar) -0.05 -0.05 -0.09 -0.30 -0.05 -0.25 -0.17 0.10 0.45
Gas Connection 3/4" 3/4" 3/4" 3/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4"
S.= STANDARD
** Note the air s e ttin g is a g uide only , th e fin a l s e ttin g is s u b je c t to th e combu s tio n testing.

HEAD SETTING - See Adjustment Of The Firing Head in Ecoflam Instructions

Page 14

CABINET HEATER

Table 2.7 Ecoflam HIGH/LOW or MODULATING Burner with Dungs Valve

Burner Reference "H" L.P.G. G31

Data for all versions "H" horizontal, "HF" high flow
Gas rates corrected to standard conditions 1013.25 mbar 15°C

INLET PRESSURE 37 mbar (minimum 25m bar, maxim um 45mb ar)

MODEL PGP 015PGP 020PGP 030PGP 040PGP 050PGP 060PGP 070PGP 080PGP 0100

Maximum Gross heat Input (kW) 55.0 74.0 104.0 145.9 183.0 221.0 256.0 300.0 367.0
Maximum Net heat Input (kW) 49.6 66.7 93.7 131.5 164.9 199.1 230.7 2 70.3 330.7
Minimum Gross hea t Input (kW) 33.85 44.40 63.82 87.13 109.88 133.19 153.16 1 79.80 219.76
Minimum net heat Input (kW) 30.50 40.00 57.50 78.50 99.00 1 20.00 138.00 162.00 198.00
Approx heat output (Net) (kW ) 43.5 58.5 82.2 115.3 144.6 174.6 202.0 2 37.0 289.9
Main Gas Orifice (mm d ia.) 8.5 10.0 10.0 14.5 14.5 14.5 14.5 14.5 N/A
Start Gas Orifice (mm d ia.) 7.0 7.0 7.0 7.0 7.0 7.0
Max Gas Rate (Sm3/hr) 2.11 2.73 3.70 5.50 6.89 8.32 9.30 11.00 12.40
Min Gas Rate (Sm3/hr) 1.30 1.65 2.31 3.28 4.19 4.99 5.73 6.68 7.98
Main Burner Gas Pressure (m bar) 4.3 5.4 5.2 3.9 7.5 6.0 7.5 10.1 5.7
Min. Burner Gas Pressure (mbar) 1.7 2.2 1.2 1.5 1.9 1.9 2.0 2.7 1.5
Start Gas Pressure (mbar) 1.1 1.7 0.6 0.7 0.7 1.5
BURNER TYPE AZUR BLU BLU BLU BLU BLU BLU BLU BLU

60 120 120 170 250R 250 250 250 350
Burner Head ssssssss s
Burner Injector LPG
Head Setting (mm) 0.0 8.0 10.0 15.0 14 T.O. T.O. T.O. T.O .
Low Flame Air Orange Ca m ** 20° 13° 22° 18° 18° 18° 22° 25° 25°
High Flame Air Red Cam ** 33° 40° 80° 30° 32° 30° 35° 55° 60°
Gas Valve Setting 0-1,4 0,3-0,9 0-1,1 0-1,1 0-1,1 0-1,4 0-1,4 0-1,5 0-0,85
Valve Type MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF
Main Gas 407 407 407 407 412 412 412 412 412

Valve Type S.I.T . S.I.T . S .I.T . S.I.T . S .I.T . S .I.T .
Start Gas 832051 832051 832051 832051 832051 832051
AIR PRESSURE SWITCH
SETTING (mbar) 1.5 1.5 1.5 1.0 1.5 1.5 1.5 2.0 2.5
Max flue static pressure
norm. flue static pressure (mbar) -0.05 -0.05 -0.09 -0.30 -0.05 -0.25 -0.17 0.10 0.45
Gas Connection 3/4" 3/4" 3/4" 3/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4"
S.= STANDARD
** Note the air setting is a guide only, the final setting is subject to the combustion testing.

HEAD SETTING - See Adjustment Of The Firing Head in Ecoflam Instructions

When setting the minimum firing rate a check must be made following the setting of the burner combustion .
The check is made by running the heater on low fire for a minimum of 15 minutes at the full transport air rate and at
typical ambient conditions. During the test check that the flue gas temperature does not fall below 150°C .Should the
flue gas temperature fall below 150°C then the low fire gas setting must be increased to a value that will achieve 150°C
flue gas temperature, otherwise condensation may form in the heat exchanger and flue causing rapid corrosion and
short operational life.

Page 15

CABINET HEATER

Fig. 2.1 Oil Fired Control Box Sequence

2.2 Control Box - Oil Fired Heaters

High /Low oil burners although following the general sequence as described below also have extra functional stages
related to air damper positions. Refer to burner manufacturers instructions for further detail.

(See also the Burner Manufacturer's Instructions)

2.2.1

The oil fired burner fitted to the heater is controlled by a fully automatic control box and photoelectric flame monitor unit.
This control ensures the safe start, ignition and stop sequence and also monitors the safe presence of a flame.

If the flame should fail, or fail to be monitored, then the control will go to the safety shut down lockout condition. The
button on the front of the control box will light to indicate this. This button will then need to be pressed in manually to
reset the control box to recommence the burner firing cycle.

This is a thermal control which, following a lockout condition, cannot be reset until the thermal element has cooled. This
takes approximately one minute.

2.2.2 Operating Sequence

The operating sequence of the oil fired control boxes are as shown in Figure 2.1.

WARNING:

The control should not be reset from lockout more than three times without identifying and correcting the

cause. Residual fuel oil in a combustion chamber is an explosion risk.

Page 16

CABINET HEATER

2.2.3 Sequence of Events

The operating sequence is as follows:

With the external controls on and calling for heat, the burner fan and electric ignition will switch on.

After a combustion air purge of approximately 12 seconds, the oil solenoid valve will open and the burner will fire.

After another 5 seconds the electric ignition is turned off and the burner will go to its normal run position.

The photo cell monitors the safe presence of the flame continuously.

When the temperature control is satisfied, the control box will turn off all its outputs simultaneously, and returns to the
rest position for the beginning of the next sequence.

2.2.4 Fault Conditions

If at any stage during normal running the photo electric cell fails to detect the flame, the control will switch off and make
an instant restart attempt. If the flame signal is still missing lockout will occur.

If the flame is not detected by the photo cell during a normal start, there will be no restart attempt and lockout will
occur in approximately 17 seconds after the start.

If a flame is detected during the first 12 seconds (purge) the solenoid valve will not open and the control will lockout.
For control sequence see Fig. 2.1.

2.3 Control Box - Gas Fired Heaters

(See also the Burner Manufacturer's Instructions)

High /Low and Modulating burners although following the general sequence as described below also have extra functional
stages related to air damper positions. Refer to burner manufacturers instructions for further detail.

Ecoflam gas burner have only one pressure switch which is configured to cover both available combustion air and
reaction to increases in combustion chamber pressure.

2.3.1 Description of Gas Fired Heater Control Box

The gas fired burner fitted to all COMBAT® cabinet heaters is controlled by a full sequence plug-in control box. This
control ensures the safe start and stop sequence and also monitors the safe presence of a flame and burner air
pressure.

The Models 15 to 30 are wired for direct ignition of the main flame. All other models are wired for ignition of a start gas
flame as first stage and then the main gas flame as the second stage.

2.3.2 Sequence of Events

The operating sequence is as follows:

With the external controls on and calling for heat, and the air pressure switch at rest, (contacts n.c. closed), the burner
fan will switch on after a short wait for the control to "self check."

Note: If the air pressure switch contacts (n.c.) are open there will be no start.

Page 17

CABINET HEATER

Fig 2.2 Gas Fired Heater Control Box Sequence

2.3.3 Air Pressure Switch Contacts

The combustion air fan now turns on and the air pressure switch contacts (n.o.) have to close within the next 5
seconds to indicate the availability of sufficient combustion air or lockout will occur.

2.3.4 Purge

The sequence continues with a purge time with the burner fan only running.

2.3.5 Electric Ignition ON

The electric ignition switches ON at the end of this purge time.

2.3.6 Start Gas Valve (Main gas for models 015 to 030)

The start gas valve opens and once a flame has been established this remains on until close down. The flame probe is
now continuously monitoring for the safe presence of flame.

2.3.7 Electric Ignition OFF

Five seconds later the electric ignition turns off, leaving the start gas flame to be proved as stable.

Page 18

CABINET HEATER

2.4 Honeywell Combination Fan/Limit Thermostat

This is a dual function control and safety device:

1. Fan Thermostat. This automatically turns the fan ON and OFF during the heater operation controlled by the
leaving air temperature. It is fitted with a white manual override button which must be in its pulled out position for
automatic operation. In its pushed in position the fan(s) will run continuously.

2. Limit Thermostat. This protects the heater from overheating caused by a reduction of air flow over the heat
exchanger. It is a manual reset device and once operated prevents the heater restarting until reset.

To reset wait until the heater has cooled sufficiently then press in and release the red reset button. After operation of the
limit thermostat, efforts should be made to locate the problem causing its operation.

Note: IT IS ESSENTIAL THAT THE LINK SHOWN IN FIG. 2.3 IS REMOVED IN THE EVENT OF A REPLACEMENT
COMBINATION FAN/LIMIT THERMOSTAT BEING FITTED

Following replacement or adjustment, the limit thermostat setting must be re-sealed using a suitable paint spot seal.

For settings see Commissioning Section 5.1.2.1.

Fig. 2.3 Combination Fan/Limit Thermostat

2.3.8 Main Gas Valve (For models above 030)

Ten seconds from when the start gas is energised the main gas valves energise and the main flame expands from the
start gas. The control is now in its normal run position.

When the external controls are satisfied the control box turns off all outputs simultaneously and returns to rest position
for the beginning of the next sequence.

2.3.9 Fault Conditions

If at any stage the flame fails , the air pressure switch detects a loss of air pressure or a rise in combustion chamber
pressure ,then the control will go to lockout. The red light on the control box will glow and the control will need to be
manually reset before any further start attempt can be made.

For control sequence see Fig. 2.2.

Page 19

CABINET HEATER

Fig. 2.4 Motor Starter (Models 040 - 0100) and Thermal Overload

(Models 060- 0100 only)

2.5 Motor Starter and Thermal Overload

On belt driven fan models the motor is controlled by a direct on line contactor starter fitted with thermal overload
protection. If the thermal overload should operate the main fan will not run. To reset, press in the reset button on the
overload unit (see Fig. 2.4). Note: For models fitted with a 5.5kW motor or larger, then the direct on line starter will be
replaced by an automatic start delta starter - see Fig. 6.14).

The overload should be set to indicate approximately 0.2 amps above the normal running current of the heater (see
Table 2.1 Technical Data).

Single phase direct drive fans are controlled directly by the fan thermostat and three phase direct drive fans are
controlled by a direct on line contactor starter, but using the motors built in thermal overload protection to operate the
contactor coil. On direct drive fan models the thermal overload is built into the motor and is an automatic reset device,
connected as shown in the Wiring Diagrams, Section 6.

2.6 Burners

For details of the Packaged Burners see the Manufacturers Instructions and the Data Tables in Section 2.1.
When reading the Data Tables ensure that the correct table for the burner and gas valve installed is being used. The
Data Tables are listed under a burner reference letter which can be found on the heater data plate.

2.7 Gas Valves Used with All Burners

2.7.1 Dungs Combination Gas Valves

The Combination Valve features as shown in Fig. 2.6.

All model 015 to 030 gas fired burners operate as direct main flame ignition and have no separate start gas train. All
other models operate with a first stage start gas flame supplied from a start gas train containing a start gas pressure
regulator and two safety shut off valves, for all gas types.

The main gas is released at the second stage and the combination main gas valve block contains a main burner
pressure regulator and two safety shut off valves, for all gas types.

Page 20

CABINET HEATER

For Ecoflam High/Low or Modulating burners then the Dungs gas valve has extra features as it is an air/gas ratio
control valve.Please refer to the manufacturers instructions regarding the setting of these controls.

The design of the gas train circuits is shown in Fig 2.5.

Orifice Plate

Most models require the fitting of a restrictor (orifice) plate between the main gas valve outlet and the burner to prevent
the burner from being over fired and provide suitable operating conditions for the gas valves.

Orifice Plate Position
Ecoflam Burner

For all models this will be fitted into the special union between the main valve and the burner at the point where the gas
supply enters the heater.

2.7.1.1 Start Gas Valves

For models PGP015 to PGP030 there is no start gas valve fitted.

For all other models the start gas train is fitted with a pressure regulator and two start gas safety shut off valves.

The start gas regulator is used to adjust the burner firing rate during the start gas phase of these models.

2.7.1.2 Main Gas Valves

Figure 2.6 shows the position of the burner pressure regulation adjustment. This must be used to set the burner
pressure as in the Data Tables as described in Section 5.

Note: For Ecoflam High/Low or Modulating burners then the Dungs gas valve has extra features as it is an air/gas
ratio control valve.Please refer to the manufacturers instructions regarding the setting of these controls.

2.7.1.3 Throughput Adjuster

Fig 2.6 shows that these types of valve have a throughput adjuster fitted to the second main gas valve.

This will be factory set at fully open on new appliances and will need no further adjustment.

When replacing a gas valve ensure that this device is set in the fully open position by releasing the locking screw and
turning the V MAX fully counter clockwise towards the " + " sign and then re-tightening the locking screw.

2.7.1.4 Rate of Opening

Fig. 2.6 also shows a slow opening adjustment. This device is a hydraulic damper which slows down the rate of
opening of the second main gas valve to give a smooth main gas ignition.

This is preset at the factory at the slowest setting and will need no further adjustment.

If a new valve is fitted than remove the plastic screw-on cap and with a small screw driver turn the V start screw fully
clockwise towards the " - " sign. Refit the plastic cover.

Page 21

CABINET HEATER

Fig 2.5 Gas Train Circuit for All Models with Dungs Gas Valves

Models 015 to 030 - all types of valve

Models 040 to 0100 - all types of valve

TO BURNER

TO BURNER

GAS
INLET

GAS
INLET

Automatic
gas valve &
regulator

Automatic
gas valve

Note orifice plate
fitted into union
between valve and
burner where required

1 = START GAS
2 = MAIN GAS

TP1 = Inlet Pressure
TP2 = Pressure between main gas valves
TP3 = Valve outlet pressure
Burner pressure TP on burner

Automatic
gas valve &
regulator

Automatic
gas valve

Note orifice fitted into
union between valve
and burner for models
40/50, and burner
flange for models 60
and over.

Automatic
gas valves

Regulator

Union

Burner
flange

TP1

TP2

TP3

1

1

2

TP1

TP2

TP3

11

2

2

1 . Pressure regulator under swivel cover

2. Slow opening adjustment

3. Throughput adjuster (always fully open)

4. Inlet flange with inlet pressure test point

5. Outlet flange with outlet pressure test point

6. Test point between main valves
Test between here and outlet test point for
pressure drop across second valve.

Fig 2.6 Dungs Main Gas Valve Details for All Models

4

5

2

5

6

1

3