Roberts Gorden Combat UHDXSR 100 Installation & Operation Manual Download Page 43 | Manualshive

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SECTION 14: R

EPLACEMENT

P

ARTS

37

14.3 Ignition Electrode and Flame Probe

14.4 Heat Exchanger

The heat exchanger consists of a six-pass design with 1.5" outer diameter [aluminized steel] [409 stainless
steel] tube. The tube plates are made of [aluminized steel] [409 stainless steel]. The tube supports are
made of [galvannealed steel] [409 stainless steel].

Inshot

B

u

rners

.120

(3 mm)

spark

gap

Ignition

Electrode

Burner Compartment

Front Views

Man

u

al Reset

Limit S

w

itch

(Position may

v

ary.)

Ignition

Electrode

Flame

Pro

b

e

Limit

S

w

itch

Flame

Pro

b

e

Inshot

Burners

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] 75

92000002

5

Inshot Burners UHD[X][S][R] 100

92000002

6

Inshot Burners UHD[X][S][R] 125

92000002

7

Limit Switch

90412104

1

Manual Reset Limit Switch (75 only)

90412106

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.

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Summary of Contents for Combat UHDXSR 100

Page 1: ...erty damage Read the Installation Operation and Service Manual thoroughly before installing or servicing this equipment Installer Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner Owner Keep this manual in a safe place in order to provide your serviceman with necessary information Roberts Gordon LLC 1250 ...

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Page 3: ...ION 7 Air Supply 17 7 1 Separated Combustion Installation 17 7 2 Unvented Installation 17 7 3 Building Ventilation 17 7 4 Outside Combustion Air Supply 17 SECTION 8 Gas Piping 18 8 1 Connections 18 SECTION 9 Wiring 19 9 1 Positioning Thermostats 19 9 2 Low Voltage Thermostat with One Heater 19 9 3 Internal Wiring Diagram 20 9 4 Ladder Wiring Diagram 21 9 5 Electrical Connection to the Heater 22 SE...

Page 4: ......

Page 5: ...orizontal Vent Termination 13 Figure 8 Standard Vented Heater Common Vertical Vent Termination 14 Figure 9 Separated Combustion Heater Vertical and Horizontal Vent Termination 15 Figure 10 Concentric Vent Box 15 Figure 11 Concentric Vertical and Horizontal Vent Termination Separated Combustion Heater 16 Figure 12 Gas Connection 18 Figure 13 Automatic Burner Control Sequence 24 Figure 14 Gas Valve ...

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Page 7: ...t approved for residential installations 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 Protective gear is to be worn during installation operation and service Thin sheet metal parts including the various venting components have sha...

Page 8: ...ix 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 Model number is found on the heater and throughout the Installation Operation and Service Manual 2 2 Corrosive Chemicals Caution Do not use heater in an area containing corrosive c...

Page 9: ...sure side of the air circulation blower Must be installed in a level position with horizontal discharge May be mounted on a shelf of non combustible material using shelf mounting brackets See Page 9 Figure 4 and Page 9 Figure 5 for details May be suspended from above See Page 8 Figure 3 or from wall brackets of sufficient strength to support the heater as listed in the Dimension Data Table on Page...

Page 10: ...allow for proper 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 10 Section 6 WARNING Carbon Monoxide Hazard Heaters may be installed vented or unvented Vented heaters must be vented outdoors Unvented heaters must be installed in buildings with ventilation rates as per section ...

Page 11: ...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 4 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 Dispens...

Page 12: ...Canada CSA approved 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 CSA approved and must be approved by the local or provincial authority ...

Page 13: ... reversed The air flow must be adjusted such that it is within the acceptable range shown on Page 7 Section 5 1 3 The minimum inlet duct lengths shown on Page 7 Section 5 1 1 should be observed Pressure drop through the heat exchanger at various air flows is given on Page 7 Section 5 1 2 Figure 2 Air Flow Direction 5 1 1 Minimum Inlet Duct Length 5 1 2 Temperature Rise and Pressure Drop Ranges 5 1...

Page 14: ...ombustibles as indicated on the wall tag and in this manual 5 3 Wall Mounting For typical suspension See Page 9 Figure 5 Wall mounted heaters blowing parallel to the wall can only be installed with the service door away from the wall The wall mounting brackets must be attached to a suitable wall using all mounting holes Screw sizes less than 3 8 may not be used In order for the wall mounting brack...

Page 15: ...et Arm Right Left Wall Suspension Mounting Wall Mounting Bracket Vertical Wall Mounting Bracket Diagonal 3 8 Fasteners Description Part Number Qty Wall Shelf Mounting Bracket Kit 12011002K Wall Suspension Mounting Bracket Kit 12011001K 1 Shelf Mounting Bracket Kit 12011000K 1 Description Part Number Qty Wall Suspension Mounting Bracket Kit 12011001K Wall Mounting Bracket Arm Left 111WALL1 1 Wall M...

Page 16: ... minimum temperature rating of 480 F 250 C 6 2 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 building NFPA 54 ANSI Z223 1 latest revision National Fuel Gas Code specifies a 4 1 2 m horizontal ...

Page 17: ... must be individually vented Vent pipe must be sloped 6 cm downward for every 1 3 m For vent lengths greater than 5 1 5 m condensation will form Insulation is recommended and condensation drains may be desired 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 ...

Page 18: ...ficiencies which could cause an unsafe condition 3 Close all building doors and windows and all doors between the space in which the appliance s connected to the venting system are located and other spaces of the building Turn on clothes dryers and any exhaust fans such as range hoods and bathroom exhausts so that they shall operate at maximum speed Do not operate a summer exhaust fan Close firepl...

Page 19: ...SECTION 6 VENTING 13 Figure 6 Vent and Roof Detail Figure 7 Standard Vented Heater Vertical and Horizontal Vent Termination Model Vent Diameter Part Number UHD X R 75 125 4 10 cm 90502102 ...

Page 20: ...UHD LOW PROFILE DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 14 Figure 8 Standard Vented Heater Common Vertical Vent Termination ...

Page 21: ...all Vent Pipe By Others Seal joint between single wall and Type B vent with silicone sealant Use 3 sheetmetal screws equally spaced around joint Use 3 sheetmetal screws equally spaced around collar Concentric Vent Box 6 15 cm Single Wall Inlet Air Pipe By Others One piece of 4 10 cm diameter 1 4 6 cm airspace type B vent Selkirk Model RV or equivalent By others Combustion Air to Heater Toward Outs...

Page 22: ... Termination Separated Combustion Heater Description Part Number Qty Concentric Vent Kit 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 ...

Page 23: ...ilation Where ventilation is required air must be taken from an outside point where it is not likely to be contaminated or obstructed 7 4 Outside Combustion Air Supply If outside combustion air supply is required separated combustion model UHD 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 ...

Page 24: ... 1 8 NPT plugged tapping accessible for test connection must be installed immediately upstream of the gas supply connection 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 g...

Page 25: ...st revision 9 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 ta...

Page 26: ...larger wires BLUE BLACK ORANGE ORANGE YELLOW BROWN WHITE WHITE L2 L1 ORANGE ORANGE BLACK BLACK GREEN WHITE BLUE BLACK GREEN BLUE GREEN YELLOW 24 VAC HOT GROUND FLAME BLACK BLACK 6 3 4 2 1 4 5 3 1 SENSE ELECTRODE LIMIT SWITCH PRESSURE SWITCH GAS VALVE IGNITION MODULE TRANSFORMER LIMIT SWITCH UHD 300 350 400 ONLY MANUAL RESET LIMIT SWITCH RESIDENTAL UNITS ONLY THERMOSTAT INPUT FIELD SUPPLIED R 24 VA...

Page 27: ...placed 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 FLAME SENSOR PRESSURE SWITCH THERMOSTAT CONNECTION 6 3 4 5 2 1 120 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 75 125 ONLY FLUE BLOWER ...

Page 28: ...T Junction box is not provided with heater Conduit can also be attached directly to heater with wire junction made within the heater cabinet BX Connector Junction Box Flexible Conduit Burner Connect wires together with suitable approved wire connectors Green to Ground White to L2 Black to L1 L1 L2 Ground Black White Green ...

Page 29: ...ged from the heater inlet pipe up to the main gas valve inlet test nipple 10 1 3 Mechanical Checks 1 Check that the flue and air intake for separated combustion units is installed in accordance with these instructions and local regulations 10 2 Begin Start Up 10 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 ...

Page 30: ...conds Signals Output By Control Required Incoming Signals Flue Blower Pressure Switch P C NO NC 30 Seconds Purge Purge time begins at pressure switch change over 30 Seconds Post 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 PSI IN C ON OFF Regulator Outlet Pressure Gas Inlet Inlet Pressure TOP VIEW END VIEW De...

Page 31: ...5 minutes and then re check settings Adjust pressure setting if necessary 2 Check gas flow rate at gas meter 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 10 2 3 Pressure Switch The pressure switch is factory pre set for each model and is not adjustable 10 2 4 Turning Off the Heater Set the thermost...

Page 32: ...rn On Heater 1 Ensure that the electrical and gas supplies to the heater are on Check that the on site controls are ON 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 24 Figure 13 The heater will now operate automatically under the control of the on site controls WARNING Explosion Hazar...

Page 33: ...g equipment 11 5 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...

Page 34: ...exchanger will remain clean unless a problem has developed with combustion Inspect the heat exchanger Look for signs of overheating at the front tubes which may indicate burner over firing or persistently low air flows 12 4 Gas Valve Maintenance No regular maintenance is required on this device To change gas control valves See Page 35 Section 14 1 Do not repair or disassemble gas valve Replace fau...

Page 35: ...ns can result in death injury or property damage 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 3 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 exchang...

Page 36: ...vice or wiring See Page 19 Section 9 1 Suspension Points Make sure the heater is hanging securely Look for signs of wear on the suspension materials or ceiling See Page 8 Figure 3 Silicone Tubing Ensure tight secure fit on all pressure fittings at pressure switch burner partition and blower outlet Gas Valve Verify that cap covering pressure regulator adjustment screw is secure and has not been tam...

Page 37: ...ed out due to ignition failure Use Troubleshooting for Automatic Ignition Burner Systems section to test burner Is ignition control showing a 2 flashes LED code Yes No Yes Fan and limit switch are operating normally Replace temperature limit switch UHD 75 Press in reset button on manual reset limit switch UHD 100 125 Wait 10 15 minutes for limit switch to cool Does fan stop running No Is ignition ...

Page 38: ...onnections faulty Repair or replace as required Check for too much vent air inlet duct Check for blockage in vent and combustion air circuit Check for faulty air pressure switch Check pressure switch hoses for leaks or cracks Do not attempt to circumvent pressure switch circuit to place unit in operation See Pressure Switch section for details Does air pressure switch change over No Yes Is 120 V s...

Page 39: ...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 Yes No Does lockout occur when there is a flame present Yes Is the connecting lead damaged Is the flame probe damaged or touching earthed components No Is the flame present and at least 1 μA DC flame current Connect a DC a...

Page 40: ... Does gas pressure at outlet of the valve rise when valve turns on No Yes Is gas pressure at inlet of the valve correct for gas type Note pressure found No Yes START If problems persist contact Roberts Gordon LLC at www rg inc com Blower Operating TROUBLESHOOT ENDS No Blower motor faulty Replace with correct type Check blower motor leads for loose connections Correct power supply problem Yes START...

Page 41: ...age 25 Section 10 2 2 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS See warnings and notes on Page 28 Section 12 before removing or replacing parts WARNING Explosion Hazard Installation service and annual inspection must be done by a contractor qualified in the installation and service of gas fired heating equipment or your gas supplier Turn off gas and elec...

Page 42: ...seal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight MODEL UHD X S R 75 UHD X S R 100 UHD X S R 125 Orifice Quantity 5 6 7 Natural Gas G20 Orifice Marking 49 46 46 P N 91930049 91930046 91930046 Propane G31 Orifice Marking 1 15 mm 1 25 mm 1 25 mm P N 91930115 91930125 91930125 Remove manifold screws and pull out manifold Manifold Inshot Burners Orifices...

Page 43: ...imit Switch Position may vary Ignition Electrode Flame Probe Limit Switch Flame Probe Inshot Burners 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 75 92000002 5 Inshot Burners UHD X S R 100 92000002 6 Inshot Burners UHD X S R 125 92000002 7 Limit Switch 90412104 1 Manual R...

Page 44: ...ng Plate to Flue Blower screws To remove the blower remove screws securing the fan and mounting plate to the vent box To remove the blower from the mounting plate remove screws Refit in reverse order To change the vent and air intake orientation from back to top remove the blower and mounting plate as above Remove intake if applicable and exhaust covers from top of the heater Rotate the blower mou...

Page 45: ...ion 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 14 8 Limit Switches 14 8 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 ...

Page 46: ...e in cm 2 5 6 35 2 5 6 35 2 5 6 35 E Minimum Inlet Duct Length in cm 32 81 28 37 93 98 37 93 98 Recommended Mounting Height to Heater Base ft m 12 3 66 20 6 10 20 6 10 Weight lb 81 92 97 REAR VIEW TOP VIEW Gas Supply 6 75 17 cm Flue Air Intake UHD X S R only D SIDE VIEW C Air Intake UHD X S R only Optional Position Flue Optional Position 4 x 3 8 Captive Nuts Provided 20 25 51 cm 28 5 72 cm 16 63 4...

Page 47: ...Air Volume in wc 0 06 0 05 0 06 Maximum Air Volume CFM 2650 3660 4750 Temperature Rise Maximum Air Volume F C 22 6 22 6 20 7 Heat Exchanger Pressure Drop Maximum Air Volume in wc 0 36 0 55 0 98 Flue Size Air Intake in cm 4 10 All models Model UHD X S R 75 UHD X S R 100 UHD X S R 125 Total Input Btu h x 1000 75 100 125 Total Output Btu h x 1000 61 5 82 102 5 Efficiency 82 All models Natural Gas G20...

Page 48: ...UHD LOW PROFILE DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 42 ...

Page 49: ...ent You 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 COMBAT UHD Series is moved or transferred This warranty is nontransferable Roberts Gordon is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERAT...

Page 50: ......

Page 51: ...Type of Installation check one o Automotive o Manufacturing o Warehouse o Recreational o Aircraft o Public Building o Ofﬁce o Retail o Agricultural o Other______________ Mail or Fax to Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo NY 14240 0044 Phone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 www rg inc com Installation Code and Annual Inspections All installations and servic...

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Page 54: ... property damage TO TURN OFF THE HEATER Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo NY 14240 0044 USA Left Right Bottom Top Clearances to Combustibles 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 of equipment sold and supplied by Roberts Gordon and conform t...

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