Roberts Gorden Combat POP 015 Guide

FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
. 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 appli-
ance.
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: [email protected]
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
X52 F 02/0
© Copyright 2002 Roberts-Gordon
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Page 1
CABINET HEATER
The 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, he 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
he gas fired heaters are category II2H 3P for natural gas or propane gas and are type B23 for
a natural draught flue.
hese instructions refer to gas appliances designed to operate in the following countries:
United kingdom (GB), Ireland (IE), Italy (I ) and Spain (ES)
he oil fired versions may also operate in these countries in accordance with local rules and
laws.
he 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
hese 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.
hese instructions cover the installation setting and operation of all variations of the COMBA ®
range of cabinet heaters. he burner manufacturers instructions are also provided to give
detailed instructions on the operation of the burner. he 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.
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Page 2
CABINET HEATER
Contents
he 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. echnical 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
HIS MANUAL RELA ES O HE AIR HEA ERS WHICH ARE MANUFAC URED FOR USE WI H:-
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 INSTR CTIONS ARE TO BE LEFT WITH THE SER 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.
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Page 3
CABINET HEATER
Section 1. General Specification
1.1 General Information - Standard Models
COMBA ® 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.
he 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
he 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
COMBA ® 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.
he heater cabinets are manufactured in Zintec coated mild steel which is finished with a stove cured powder coat
paint.
he combustion chambers are of high grade stainless steel construction. he 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.
he 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
he 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.
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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 ressure Relief
Stainless Steel
Combustion Chamber
Double Skin anels
Burner Tube (for
mounting the 'packaged'
burner)
Electrical Connections
Lower Front anel
Main Fan Assembly
(Direct Drive on
Models 15 - 50,
Belt Dive on
Models 60 -100)
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CABINET HEATER
1.2 Basi Information - High Flow (HF) Models
1.2.1 Introduction
he COMBA ® 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 COMBA ® cabinet range of heaters.
he 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.
COMBA ® 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
he 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
he HF range of heaters are designed to be operated with external controls and are provided with electrical terminals
to accommodate these.
hey 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.
he 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.
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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. his
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. he 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. his 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. he 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
he 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.
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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 a
24
5.3 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 a
28
6.3 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 a
21
6.2 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 a
21
6.2 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 a
24
5.3 2.1
3398
(2000)
230
50
1
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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
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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.
Model Num be r 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 HF6 See Graph HF7 See Graph HF8 See Graph HF 9 See Graph HF10
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 Motor 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 Pulley 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 Pulley 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 Amp 6.0 - 10 Amp 4.0 - 7.5 Amp 6.0 - 10 Amp Star.Delta 7.5 A. FLC 6.0 - 10 Amp Star.Delta 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 ENSIONS
'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 fired) 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 burner settings are as show n in the relevant data table in the main instructions book. these models are fitted with star delta starters as standard
Heat inputs shown are maximum for each version at minimum air flow on graph. Revision correct motor shaft size for 50 v2 October 10 96
Dimensions - High Flow Cabinet Heaters - All Models
AB
C
DW
L
F
G
178
229 (HF30) 435 (HF40) 412 (HF50)
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CABINET HEATER
Table 2.3 Oil Fired Burner Data (E oflam Burner)
Burner Reference "G"
DATA TABLES - IMPORTANT NOTE
When reading the Data ables 2.3 to 2.9 on the following pages,
ensure that the correct table for the burner and gas valve installed is being used.
he Data ables 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.
he 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
Nom inal Heat 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
NozzleSize
Usgall/hr 1.00 1.502.253.00 3.00 4.00 5.00 5.50 7.00
Angle&Type
60S 60S60S60S 60S 60A 60A 60A 60A
Make
DanfossDanfossDanfossDanfossDanfossDelevan Delevan Delevan Delevan
Headsetting
mm8014
8 (Fully back) 8 (Fully back) 8 (Fully back) 8 (Fully back) 8 (Fully back) (Fully Forward)
Airsetting
Number 4.28.55.52.5 4 3.74.56.21.8
Burner fuel
Bar 1210.310.3 10 13.8 12.410.710 11
pressure
PSI175 150150 145 200 180 155 145 160
Fue l L/hr 4.82 6.96 10.37 13.83 17.32 20.92 24.23 28.43 33.65
consum ption 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 0.21 0.21 0.21
to pum p inle t PSI3333333 33
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Page 11
CABINET HEATER
Table 2.4 E oflam ON/OFF Natural Gas (G20) Dungs Valve, Burner
Referen e C
Data for all versions "H" horizontal, "HF" high flow
Gas rates corrected to standard conditions 1013.25 mbar 15°C
HEAD SE ING - See Adjustment Of The Firing Head in Ecoflam Instructions
INLET PRESSURE 20 mbar (Minimum 17 mbar, Maximum 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
Approx heat output (kW) 46.9 60.3 81.9 114.7 144.8 176 202.8 237.6 290.1
Start Gas Orifice (mmdia.) 5.0 6.0 7.0 7.0 7.0 7.0
Max Gas Rate (Sm3/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 T YPE AZUR BLU BLU BLU BLU BLU BLU BLU BLU
60 120 120 170 250R 250 250 250S 350
BurnerHead sssssssss
Burner Injector
Head Setting (mm) 0 1011151424242421
1st Flame Air Setting 3.53.982.85.13.35.322
2nd Flame Air Setting
Gas Valve Setting
Valve Type MBDLE MBDLE MBDLE MBDLE MBDLE MBDLE MBDLE MBDLE MBDLE
Main Gas 405 405 405 407 410 410 410 410 412
ValveType SSSSSS
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.IT
H.= HONEYWELL
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CABINET HEATER
Table 2.5 E oflam ON/OFF LPG (G31) with Dungs Valve, Burner Referen e C
Data for all versions "H" horizontal, "HF" high flow
Gas rates orre ted to standard onditions 1013.25 mbar 15°C
HEAD SE ING - 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 (mmdia.) 8.5 10.0 10.0 14.5 14.5 14.5 14.5 14.5
Start Gas Orifice (mmdia.) 5.0 6.0 7.0 7.0 7.0 7.0
Max Gas Rate (m3/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
Main Burner Gas Pressure (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 250RAH 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 Flame Air Setting
Gas Valve Setting
Valve Type MBDLE MBDLE MBDLE MBDLE 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
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CABINET HEATER
Table 2.6 E oflam HIGH/LOW or MODULATING Burner with Dungs
Valve, Burner Referen e "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 .
he 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 (Net) (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 (Sm3/hr) 5.2 7.1 9.9 13.9 17.4 21.1 24.4 28.6 35.0
Min Gas Rate (Sm3/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. BurnerGas Pressure (mbar) 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
BurnerHead ssssssss s
Burner Injector
Head Setting (mm) 0.0 8.0 10.0 15.0 14 T.O. T.O. T.O. T.O.
LowFlame Air Orange Cam ** 20°13°22°18°18°18°22°25°25°
High Flame Air Red Cam ** 33°40°80°30°32°30°35°55°60°
GasValveSetting 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 MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF MBVEF
Main Gas 407 407 407 407 412 412 412 412 412
ValveType 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, thefinal setting is subject to the combustiontesting.
HEAD SE ING - See Adjustment Of The Firing Head in Ecoflam Instructions
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CABINET HEATER
Table 2.7 E oflam HIGH/LOW or MODULATING Burner with Dungs Valve
Burner Referen e "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 25mbar, maximum 45mbar)
MODEL PGP015PGP020PGP030PGP040PGP050PGP060PGP070PGP080PGP0100
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 (Net) (kW) 43.5 58.5 82.2 115.3 144.6 174.6 202.0 237.0 289.9
Main Gas Orifice (mm dia.) 8.5 10.0 10.0 14.5 14.5 14.5 14.5 14.5 N/A
Start Gas Orifice (mm dia.) 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 (mbar) 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
BurnerHead 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 Cam ** 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 SE ING - 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 .
he 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.
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CABINET HEATER
Fig. 2.1 Oil Fired Control Box Sequen e
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
he oil fired burner fitted to the heater is controlled by a fully automatic control box and photoelectric flame monitor unit.
his 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. he
button on the front of the control box will light to indicate this. his button will then need to be pressed in manually to
reset the control box to recommence the burner firing cycle.
his is a thermal control which, following a lockout condition, cannot be reset until the thermal element has cooled. his
takes approximately one minute.
2.2.2 Operating Sequence
he 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.
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Page 16
CABINET HEATER
2.2.3 Sequence of Events
he 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.
he 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
he gas fired burner fitted to all COMBA ® cabinet heaters is controlled by a full sequence plug-in control box. his
control ensures the safe start and stop sequence and also monitors the safe presence of a flame and burner air
pressure.
he 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.
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Page 17
CABINET HEATER
Fig 2.2 Gas Fired Heater Control Box Sequen e
2.3.3 Air ressure Switch Contacts
he 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 urge
he sequence continues with a purge time with the burner fan only running.
2.3.5 Electric Ignition ON
he electric ignition switches ON at the end of this purge time.
2.3.6 Start Gas Valve (Main gas for models 015 to 030)
he start gas valve opens and once a flame has been established this remains on until close down. he 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.
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Page 18
CABINET HEATER
2.4 Honeywell Combination Fan/Limit Thermostat
his is a dual function control and safety device:
1. Fan Thermostat. his 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. his 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.
o 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: I IS ESSEN IAL HA HE LINK SHOWN IN FIG. 2.3 IS REMOVED IN HE EVEN OF A REPLACEMEN
COMBINA ION FAN/LIMI HERMOS A BEING FI ED
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)
en seconds from when the start gas is energised the main gas valves energise and the main flame expands from the
start gas. he 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. he 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.
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