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

Page 1: ...call the Fire Department Fire Hazard Keep all flammable objects liquids and vapors the minimum required clear ances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage WARNING Installation must be done by a contractor qualified in the installation and service of gas f...

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Page 3: ...AVERTISSEMENT L installation doit être effectuée par un entrepreneur qualifié dans l installation et l entretien d appareils de chauffage au gaz ou par votre fournisseur de gaz L installation le réglage la modification la réparation ou la maintenance inadapté peut entraîner la mort des blessures ou des dommages matériels Lire attentivement le manuel d installation d utilisation et d entretien avan...

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Page 5: ...g Thermostats 21 10 2 Low Voltage Thermostat with One Heater for Models UHD T X S R 150 250 21 10 3 Low Voltage Thermostat with One Heater for Models UHD X S R 300 400 22 10 4 UHD X S R Series Internal Wiring Diagram for Single Stage Gas Valves 23 10 5 UHD X S R Series Ladder Wiring Diagram for Single Stage Gas Valves 24 10 6 UHD T X S R Series Internal Wiring Diagram for Two Stage Gas Valves 25 1...

Page 6: ...ions 52 16 1 Dimension Data for Models UHD T X S R 150 250 52 16 2 General Technical Data Table 53 16 3 Technical Data Table 53 16 4 Dimension Data for Models UHD X S R 300 400 54 16 5 General Technical Data Table 55 16 6 Technical Data Table 55 SECTION 17 The ROBERTS GORDON UHD Series Warranty 57 ...

Page 7: ...6 Figure 11 Concentric Vent Box 16 Figure 12 Concentric Vertical and Horizontal Vent Termination Separated Combustion Heater 17 Figure 13 Gas Connection 20 Figure 14 Automatic Burner Control Sequence 29 Figure 15 Single Stage Gas Valve for Models UHD X S R 150 400 29 Figure 16 Two Stage Gas Valve for Models UHD T X S R 150 250 30 Figure 17 LED Diagnostic Codes 32 There are references in this manua...

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Page 9: ...alled using the best building practices This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the app...

Page 10: ... Number Logo Label 91040030 Vent Length Label 91039505 Vent to Outdoors Label 91010427 Warning Label 91010429 Rating Plate Label 91039802 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label 91010426 Proposition 65 Label 91070015 For separated combustion units only ...

Page 11: ...40030 Vent Length Label 91039505 Vent to Outdoors Label 91010427 Warning Label 91010429 Rating Plate Label 91039802 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label 91010426 Proposition 65 Label 91070015 For separated combustion units only ...

Page 12: ... Printed in U S A Imprimé aux Etats Unis For separated combustion units only Description Part Number Logo Label 91040030 Vent Length Label 91039505 Vent to Outdoors Label 91010427 Warning Label 91010429 Rating Plate Label 91039802 Installation Label 91010431 Instruction Location Label 91010433 Lighting Instruction Label 91010425 Venting Arrangement Label 91010426 Proposition 65 Label 91070015 ...

Page 13: ...ive strips on the rear surface and position the tag on a wall near the heater A copy of the wall tag P N 91039831 is illustrated on the back cover Know your model number and installed configuration Model number and installed configuration are found on the heater serial plate and throughout the Installation Operation and Service Manual 2 2 Corrosive Chemicals Roberts Gordon LLC cannot be responsibl...

Page 14: ...el package Stainless steel package includes heat exchanger tube supports and drip pan 3 3 Location and Suspension All models Must be installed indoors Must be installed on the positive pressure 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 May be suspended from above See Page 11 Section 6 2 o...

Page 15: ...re Building materials with a low heat tolerance such as plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s and owner s responsibility to assure that adjacent materials are protected from degradation Maintain clearances from heat sensitive equipment and work stations Consult local Fire Marshal Fire Insurance Carrier or other authoritie...

Page 16: ...ey shall not be subject to injury by aircraft cranes movable scaffolding or other objects Provisions shall be made to assure accessibility to suspended heaters for recurrent maintenance purposes 5 3 Parking Structures and Repair Garages Installation in garages must be in accordance with the following codes United States Standard for Parking Structures NFPA 88A latest revision or the Code for Motor...

Page 17: ...anada Heaters installed above 2000 610 m must be de rated For installations above 2000 610 m in US consult factory for information on burner de rating For installations from 2000 610 m to 4500 1370m in Canada high altitude conversion kits are available Heaters installed over 4500 1370 m in Canada are not approved and must be approved by the local or provincial authority ...

Page 18: ...flows is shown on Page 10 Section 6 1 2 Figure 5 Air Flow Direction 6 1 1 Minimum Inlet Duct Length 6 1 2 Temperature Rise and Pressure Drop Ranges Model Duct Length Duct Size W X H UHD T X S R 150 175 52 132 cm 28 x 24 71 cm x 60 cm UHD T X S R 200 250 60 162 cm 28 x 32 1 2 71 cm x 83 cm UHD X S R 300 400 75 190 cm 35 x 40 1 2 89 cm x 82 cm UHD T X S R 150 UHD T X S R 175 UHD T X S R 200 UHD T X ...

Page 19: ...nstalled in accordance with clearances to combustibles as indicated on the serial plate wall tag and throughout the manual See Page 7 Section 4 Figure 6 Suspension Methods WARNING Crush Hazard Use 3 8 threaded rod minimum Failure to follow these instructions can result in death injury or property damage Nut Washer Riv Nut Ensure all 3 8 16 threaded suspension hardware is torqued to a minimum of 19...

Page 20: ...adian Requirements The vent shall not terminate within 6 1 8 m of a mechanical air supply inlet to any building The vent shall not terminate within 3 9 m of a window or door that can be opened in any building any non mechanical air supply inlet to any building or of the combustion air inlet of any other appliance 7 2 Vent Installation Maintain clearances to combustibles at all times for safety Cle...

Page 21: ...ical Venting Vertically vented standard vented heaters can be common vented up to four heaters For 4 10 cm common vent an approved vent cap P N 90502102 must be used For 6 15 cm common vent an approved vent cap P N 90502103 must be used For common vertical venting of more than two heaters See Page 15 Figure 9 A vent shall not extend less than 2 6 m above the highest point where it passes through a...

Page 22: ...CT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 14 of 57 Figure 8 Standard Vented Heater Vertical and Horizontal Vent Termination Model Vent Diameter Part Number UHD T X R 150 250 UHD X R 300 400 4 10 cm 90502102 ...

Page 23: ...t opposition between streams of combustion gases Roof 2 6 m Minimum Type B vent cap 7 18 cm or 8 20 cm may be used These are not available from the manufacurer Roof Flashing Approved Thimble If Applicable Type B Vent Pipe 4 10 cm Single Wall Pipe 4 10 cm Single Wall Pipe D Area must equal sum of open area of individual vents D Single Wall Pipe The last section of vent pipe passing through the roof...

Page 24: ...mbustion Heater Vertical and Horizontal Vent Termination Figure 11 Concentric Vent Box Model Vent Diameter Part Number UHD T X S R 150 250 4 10 cm 90502102 UHD X S R 300 400 4 10 cm 90502102 Model Air Intake Diameter Part Number UHD T X S R 150 250 4 10 cm 90502102 UHD X S R 300 400 5 13 cm 90502105 ...

Page 25: ...0 3 m Maximum NOTE Vent supports not shown Duct supports not shown Duct and vent supports not provided by the manufacturer 12 31 cm Minimum from wall to combustion air terminal Description Part Number Qty Concentric Vent Kit 150 250 UHVK1 Concentric Vent Box Top Side Assembly 90504113 1 Concentric Vent Box Bottom Assembly 90504112 1 Screw 6 x 3 8 Self Drilling 91119100 14 4 10 cm Vent Terminal wit...

Page 26: ...ion model UHD T X S R heaters must be used Caution If the building has a slight negative pressure or corrosive contaminants such as halogenated hydrocarbons are present in the air an outside combustion air supply to the heater is required Seal all combustion air pipe joints For models 300 400 the flexible air duct may be insulated to prevent condensation on the outer surface The outside air termin...

Page 27: ... a maximum pressure drop of 1 2 wc When gas piping is not included in the layout drawing contact the local gas supplier An isolating valve and union connection should be used and fitted into the supply adjacent to the heater For suspended heaters an approved metal flexible connection between the isolating valve and the heater may be used To reduce pressure loss use one pipe size larger than the he...

Page 28: ...UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 20 of 57 Figure 13 Gas Connection ...

Page 29: ...ration free wall or column at a height of approximately 5 1 5 m from the floor to measure the ambient temperature It should be clear of both cold drafts and the direct path of warm air from the heater Avoid mounting thermostat on outside walls or in areas directly exposed to radiant heat or sunlight Install wall tag in a visible location near thermostat See Page 5 Section 2 1 for wall tag details ...

Page 30: ...UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 22 of 57 10 3 Low Voltage Thermostat with One Heater for Models UHD X S R 300 400 ...

Page 31: ...Gas Valves IMPORTANT For field wiring into service junction box or if any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C 221 F and 600 V For supply connections use No 14 AWG or larger wires ...

Page 32: ...upplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C 221 F and 600 V For supply connections use No 14 AWG or larger wires 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 ...

Page 33: ... LOW CONTROL HIGH LOW COMMON IMPORTANT For field wiring into service junction box or if any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C 221 F and 600 V For supply connections use No 14 AWG or larger wires ...

Page 34: ...ram for Two Stage Gas Valves HIGH STAGE NOTE For field wiring into service junction box or if any of the original wire supplied with the heater must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C 221 F and 600 volts For supply connections use No 14 AWG or larger wires ...

Page 35: ... 10 WIRING 27 of 57 10 8 Electrical Connection to the Heater IMPORTANT Junction box is not provided with heater Conduit can also be attached directly to heater with wire junction made within the heater cabinet ...

Page 36: ... the main gas valve inlet test nipple 11 1 3 Mechanical Checks 1 Check that the flue and air intake for separated combustion units is installed in accordance with the instructions in this manual and local regulations See Page 12 Section 7 11 2 Begin Start Up 11 2 1 Before Operating the Heater To ensure that all the controls are in safe working order operate the heater for the first time with the i...

Page 37: ...quired Incoming Signals Flue Blower Pressure Switch P C NO NC 30 Seconds Purge Purge time begins at pressure switch change over 30 Seconds Post Purge If at any stage the flame fails the control will retry for ignition The control has four trials for ignition before a one hour lockout PSI IN C ON OFF Regulator Outlet Pressure Gas Inlet Inlet Pressure TOP VIEW END VIEW Description Part Number Gas Va...

Page 38: ...RVICE MANUAL 30 of 57 Figure 16 Two Stage Gas Valve for Models UHD T X S R 150 250 PSI IN C ON OFF LO HI Regulator Outlet Pressure Gas Inlet Inlet Pressure TOP VIEW END VIEW Description Part Number Gas Valve 150 250 NG 90032530 Gas Valve 150 250 LP 90032531 ...

Page 39: ... be corrected before completing the start up 11 2 3 2 Check Gas Rate 1 After burner pressure adjustment allow the heater to operate for at least 15 minutes and then re check settings Adjust pressure setting if necessary 2 Check gas flow rate at gas meter For two stage valve High Low operation check gas flow in both operating modes 3 Turn off heater and electrical supply 4 Remove the manometer and ...

Page 40: ...caused by an interruption of the electrical supply failure of the distribution fan or vent or heat exchanger blockage If a temperature limit switch persistently trips there is a fault which must be investigated by a contractor qualified in the installation and service of gas fired heating equipment 12 3 1 Simple Troubleshooting Burner Faults If the burner fails to ignite for any reason it will ret...

Page 41: ... 4 Remove manifold from burner assembly via four screws two on top and two on bottom See Page 44 Section 15 2 2 Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner 5 Check condition of ignition electrode and flame probe Clean off any deposits which may have formed check condition of ceramic insulators Replace as required See Page 46 Section 15 4 ...

Page 42: ...ervice of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service equipment sold and supplied by Roberts Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service operation and labeling of the equipment To help facilitate optimum performance and s...

Page 43: ... Window Make sure it is clean and free of cracks or holes Clean and replace as required Flue Blower Scroll Wheel and Motor Compressed air or a vacuum cleaner may be used to clean dust and dirt Inshot Burners and Orifices Clear obstructions even spider webs will cause problems Carefully remove any dust and debris from the burner Direct Spark Igniter Replace if there are cracked ceramics excessive c...

Page 44: ...roper cleaning procedures Air Circulation Blower For a complete inspection see the manufacturer s Installation Operation and Service manual Wall Tag If wall tag is present make sure it is legible and accurate Please contact Roberts Gordon LLC or your ROBERTS GORDON independent distributor if you need a wall tag See Page 5 Section 2 1 ...

Page 45: ...re to follow these instructions can result in death electric shock injury or property damage Burn Hazard Allow heater to cool before service Tubing may still be hot after operation Explosion Hazard Turn off gas supply to heater before service DANGER Electrical Shock Hazard Disconnect electric before service Heater must be connected to a properly grounded electrical source ...

Page 46: ...UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 38 of 57 14 1 General ...

Page 47: ...NG 39 of 57 14 2 Troubleshooting For Automatic Ignition Burner Systems For optimum heater performance use only replacement parts sold and supplied by Roberts Gordon LLC Conduct start up procedure as shown on Page 28 Section 11 ...

Page 48: ...n to trace the fault Heater Operating TROUBLESHOOT ENDS No Repair or replace as required Is inlet burner gas pressure correct Is live and neutral polarity correct Is flame probe circuit correct Is there a current flowing in the flame probe circuit with no flame present Yes No Does lockout occur when there is a flame present Yes Is the connecting lead damaged Is the flame probe damaged or touching ...

Page 49: ... correct for gas type Note pressure found No Yes START If problems persist contact Roberts Gordon LLC at www robertsgordon com or www rg inc com For optimum heater performance use only replacement parts sold and supplied by Roberts Gordon LLC Conduct start up procedure as shown on Page 28 Section 11 Blower Operating TROUBLESHOOT ENDS No Blower motor faulty Replace with correct type Check blower mo...

Page 50: ... See Page 31 Section 11 2 3 IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVE IS USED WHEN REPLACING THESE CONTROLS Carbon Monoxide Hazard WARNING Use only genuine ROBERTS GORDON replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage Explosion Hazard DANGER Electrical Shock Hazard Fire Haz...

Page 51: ... T X S R 150 250 Side View of Burner Compartment with Hinged Door Removed Before burner removal remove the 10 screws holding the filler panel on and remove the filler panel Side View of Burner Compartment with Filler Panel Removed Burner assembly must be removed to service orifices manifold or burners Following any work refit components in reverse order ...

Page 52: ...ctors Ensure correct alignment with burners Ensure all pipe joints are gas tight MODEL UHD T X S R 150 UHD T X S R 175 UHD T X S R 200 UHD T X S R 225 UHD T X S R 250 Orifice Quantity 7 8 9 10 11 Natural Gas Orifice Marking 43 43 2 25 mm 2 25 mm 2 25 mm P N 91930043 91930043 91930225 91930225 91930225 Propane Orifice Marking 1 35 mm 1 35 mm 54 54 54 P N 91930135 91930135 91930054 91930054 91930054...

Page 53: ...eal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight NOTE Flexible duct only applies for model UHDS Screws Manifold Inshot Burners Orfices Burner Screws Burner venturi Unscrew Orfice Manifold Marking Inshot Burner Ensure gas tight fitting of injectors Ensure correct alignment with burners Ensure all pipe joints are gas tight Burner assembly must be remov...

Page 54: ...Module 90434008 1 Inshot Burners UHA T X S 150 92000001 7 Inshot Burners UHA T X S 175 92000001 8 Inshot Burners UHA T X S 200 92000000 9 Inshot Burners UHA T X S 225 92000000 10 Inshot Burners UHA T X S 250 92000000 11 Limit Switch 150 400 300 400 LOWER 90412103 1 To replace the ignition electrode or flame probe remove the electrical lead and screw Pull out from mounting Refit in reverse ensuring...

Page 55: ...t Burners Flame Probe Description Part Number Qty Spark Electrode 90427411 1 Automatic Ignition Flame Probe 90439300 1 Transformer 90436900K 1 Ignition Module 90434008 1 Inshot Burners UHD X S R 300 92000000 12 Inshot Burners UHD X S R 350 92000000 14 Inshot Burners UHD X S R 400 92000002 14 Limit Switch 150 400 300 400 LOWER 90412103 1 Limit Switch 300 400 UPPER 90412105 1 To replace the electrod...

Page 56: ...D FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS Carry out a start up after working on or changing a flue blower See Page 28 Section 11 MODEL UHD T X S R 150 175 Flue Blower P N 90710405 Rear Panel Gasket Mounting Plate Flue Fan Vent Box Rear Panel Flue Fan Vent Box Gasket Remove screws securing outlet flange to the flue adapter Refit in reverse order Disconnect electrical connections at p...

Page 57: ...MODEL UHD T X S R 200 250 Flue Blower P N 90710403 Outlet Gasket Inside of Rear Panel Mounting Plate Flue Fan Gaskets Fan Plate Screws Remove screws securing outlet flange to the flue adapter Refit in reverse order Disconnect electrical connections at plug in tabs Remove screws securing flue fan mounting plate to vent box Remove screws securing mounting plate to fan Not shown Refit in reverse Use ...

Page 58: ...10403 90710402 Vent Box Outlet Gasket Flue Blower Vent Box screws Flue Adapter Flue Adapter to Flue Blower screw Rear Panel Hole Disconnect electrical connections at plug in tabs Mounting Plate to Vent Box screws Gasket Gasket Mounting Plate to Flue Blower screws Vent Box Air Plate Remove screws securing outlet flange to the flue adapter Refit in reverse order Remove screws securing flue blower mo...

Page 59: ...ase the four mounting standoffs Refit in reverse Ensure correct location of ignition cable and all other wiring 15 12 Limit Switches 15 12 1 Removal and Replacement 1 Remove the electrical connections to the switch 2 Unscrew the two screws securing the switch 3 Fit a new switch with two screws 4 Reconnect the electrical connections and test operation MODEL UHD T X S R 150 175 UHD T X S R 200 225 U...

Page 60: ...5 5 64 8 25 5 64 8 25 5 64 8 25 5 64 8 D in cm 17 6 44 7 17 6 44 7 17 6 44 7 17 6 44 7 17 6 44 7 E in cm 19 4 49 3 19 4 49 3 19 4 49 3 19 4 49 3 19 4 49 3 G in cm 6 0 15 2 6 0 15 2 6 6 16 8 6 6 16 8 6 6 16 8 H in cm 7 86 20 7 86 20 8 6 22 8 6 22 8 6 22 J in cm 11 65 29 6 11 65 29 6 17 7 45 17 7 45 17 7 45 K in cm 3 4 8 6 3 4 8 6 8 1 20 6 8 1 20 6 8 1 20 6 L in cm 5 7 14 5 5 7 14 5 5 7 14 5 5 7 14 ...

Page 61: ...lume F C 20 11 20 11 20 11 20 11 22 12 Heat Exchanger Pressure Drop Maximum Air Volume in wc 0 16 0 29 0 163 0 253 0 35 Flue Size in cm 4 All Models 10 Air Intake in cm 4 All Models 10 Duct Size Width 28 71 28 71 28 71 28 71 28 71 28 71 Duct Size Height 24 61 24 61 32 5 83 32 5 83 32 5 83 32 5 83 Weight Net lb kg 191 86 6 211 95 7 239 108 4 249 112 9 254 115 2 Model UHD T X S R 150 UHD T X S R 175...

Page 62: ...ue Thermostat Connection Gas Supply D M F C F Duct Flange N Model A B C D E F G H J K L M N UHD X S R 300 in cm 52 3 132 8 43 2 109 7 25 5 64 8 24 7 62 7 19 4 49 3 1 25 3 2 7 0 17 8 11 2 28 4 13 8 35 1 6 2 15 7 8 7 22 1 2 4 6 1 6 5 16 5 UHD X S R 350 in cm 52 3 132 8 43 2 109 7 25 5 64 8 24 7 62 7 19 4 49 3 1 25 3 2 7 0 17 8 11 2 28 4 13 8 35 1 6 2 15 7 8 7 22 1 2 4 6 1 6 5 16 5 UHD X S R 400 in c...

Page 63: ...emperature Rise Maximum Air Volume F C 23 13 22 12 22 12 Heat Exchanger Pressure Drop Maximum Air Volume in wc 0 27 0 48 0 53 Flue Size in cm 4 All Models 10 Air Intake in cm 5 13 5 13 5 13 Duct Size Width 28 71 35 89 35 89 35 89 Duct Size Height 24 61 40 5 103 40 5 103 40 5 103 Weight Net lb kg 325 147 4 345 156 5 345 156 5 Model UHD X S R 300 UHD X S R 350 UHD X S R 400 Total Input Btu h x 1000 ...

Page 64: ...UHD STANDARD DUCT FURNACE INSTALLATION OPERATION AND SERVICE MANUAL 56 of 57 ...

Page 65: ...nance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the ROBERTS GORDON UHD Series is moved or transferred This warranty is nontransferable Roberts Gordon LLC is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your controller contac...

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